9/23/2012

MECHATRONICS & ROBOTICS

Lecture 5

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Todays Topic:
1. Shaft Speed Control (OLS)
2. Advantages/Disadvantages of Closed loop System
3
3. Advantages/Disadvantages of Open loop System
4. Controllers
5. Sequential Controllers
6. Microprocessor
7. Microprocessor Based Controllers
8. The Engine
g Management
g System
y
9. Levels of Automations

Shaft Speed Control (OLS)

Manually Æ Initial Setting of Knob Æ Affects the voltage
applied to the motor Æ If There is Temp., Voltage or Shaft
load Change Æ change of shaft speed

Shaft Speed Control (CLS)

Potentiometer Æto set the reference value supplied to the
differential amplifier Æ Differential amplifier is used for
compare & amplify the difference b/w the reference and
feedback values Æ It amplifies the error signal Æ This
amplified signal is fed to motor which in turn adjusts the
speed of the rotating shaft Æ speed of shaft is measured by
Tachogenerator Æ then signal is fed to back to the
differential amplifier.

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Shaft Speed Control (OLS)

Example of Closed Loop System

Lead Screw of Lathe Machine
Actual x

Motor Input Work Table

X – value
Controller Motor Optical
encoder

Feedback Signal to Controller

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Steps of Operations
1. A DC servomotor connected to lead screw is a common
actuator for each axis.
2. A signal indicating the coordinate value (x-value) is sent
f
from the
h controller
ll to motor that
h drives
di the
h lead
l d screw
whose rotations is converted into linear motion of the
positioning table.
3. As the table moves closer to the desired x- coordinate
value, the difference b/w actual x-position & the input x-
value is reduced.
reduced
4. The actual x-position is measured by a feedback sensor
(e.g. an optical encoder).
5. The controller continues to derive the motor until the
actual table position achieved corresponds to the input
position value.

Advantages of Closed loop System

1. Greater accuracy
2. Less sensitive to Noise, disturbance, & Change
in environment
3. Transient response
4. Greater Flexibility

Disadvantages
1. Expensive
2. Complex

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Open Loop Control System

1. An open loop control system operates without the
feedback loop.
2. The controls operate without measuring the o/p
variables.
variables
3. No comparison is made b/w actual value, the output, &
the desired i/p parameter.
4. Output signals has no effect on input signals.
Open Loop systems are better when the following
conditions applies:
1. Actions performed by control system are simple.
2. Actuating function is very reliable.
3. Any reaction forces opposing the action are small
enough to have no effect on the actuation.

Open Loop Control System

I/P Actuator O/P

Controller Process
Parameters Variable

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Advantages of Open loop System

1. Simple
2. Less Expensive

Disadvantages
1. Don’t Compensate for any disturbance
2. Cannot correct for any change

Q i
Quiz
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Quiz
Write down the differences b/w
Open & Closed Loop System

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Difference B/W OP & CL System

1. Compensate for disturbances 1. Can’t Compensate for
disturbances
2. Can correct for disturbance 2. Can’t correct for disturbance
3 Feedback is there
3. 3 No
3. N F
Feedback
db k
4. Greater accuracy 4. Less Accuracy
5. Structure is complex 5. Structure is Simple
6. More expensive 6. Less Expensive
7. Poor reliability 7. Good Reliability
8. Greater chance
h off break
b k down
d 8. Less chance of break down
due to greater number of parts due to a few number of parts
9. O/p signal has an effect on i/p 9. O/p signal has no effect on i/p
signal signal

Microcontroller
• A single chip that contains the processor (the
CPU) non‐volatile
CPU), l til memory for
f the
th program
(ROM or flash), volatile memory for input and
output (RAM), a clock and an I/O control unit.
Also called a "computer on a chip

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Sequential Controllers

The operating sequence is called a

program, the h sequence off instructions
i i
in each program being predefined and
'built' into the controller used.

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Sequential Controllers
The term sequential control is used when control actions are
performed strictly in ordered in a time or event driven
sequence. Such control could be obtained by an electrical circuit
with sets of relays or cam-operated switches which are wired
up in such a way as to give the required sequence.
sequence Such hard-
hard
wired circuits have been replaced by a microprocessor
controlled system. with the sequencing being controlled by
means of a software program. As an illustration of sequential
control, consider the domestic washing machine. A number of
operations have to be carried out in the correct sequence. These
may involve:
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1. A pre-wash
pre wash cycle when the clothes in the drum are given a
wash in cold water
2. A main wash cycle when they are washed in hot water.
3. A rinse cycle when the clothes are rinsed with cold water a
number of times.
4. A spinning to remove water from the clothes.

Sequential Controllers
operation involve:
1. Pre wash in cold water & opening a valve to fill the machine drum to
the required level
2 Closing the valve
2.
3. Switching on the drum motor to rotate the drum for a specific time
4. Operating the pump to empty the water from the drum
5. Opening the valve to fill the drum
6. Switching on the element to heat up the water
7 Switching off the element
7.
8. Starting the motor for main wash in hot water
9. Switch on the pump to drain the water
10. Open the valve for fresh water
11. Rinse the clothes in cold water a number of times

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Sequential Controllers

Sequential Controllers

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Microprocessor
1. It is a collection of logic gates & memory elements
whose logical functions are implemented by means of
software.
2. It is an electronic device capable of manipulating data
to produce desired results. The functions of a digital
computer are performed using the microprocessor’s
arithmetic, logic and control circuitry. It essentially
consists of several hundred thousands, or perhaps
even billions of tiny transistors on a single integrated
circuit.
3. Every microprocessor depends on an ‘instruction set’,
which is designed to program it to perform
specialized functions.

Microprocessor Based Controllers

Now a days Microprocessors are rapidly Inputs
replacing the mechanical cam-operated A B C D
controllers and being used in general to carry
out control functions.
functions They have the great
advantage that a greater variety of programs
Control
become feasible. A more adaptable form is Program
the programmable logic controller (PLC) Micro-
Controller
PLC is a microprocessor based controller
which uses programmable memory to store
instructions and to implement functions such
as logic, sequence, timing, counting and
arithmetic to control events. It can be P Q R S
reprogrammed for different task. outputs

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Benefit of Microprocessor Based

Controllers
1. Greater variety
y of p
programs
g become feasible
2. Provided with programmable memory unit
3. All logical functions are implemented on a
single chip
4. Smart in size
5. Faster processing

The automatic Camera

An Example of Micro‐Processor
Procedure/Working
1. Switch is operated to activate the system
2. The camera pointed at the object being photographed
3. The micro-processor takes in, the input from the range
sensor
4 This input sends an output to the lens position drive to
4.
move the lens to achieve focusing.
5. The lens position is fed back to the microprocessor so
that the feedback signal can be used to modify the lens
position according to the input from the range sensor.

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The automatic Camera

An Example of Micro‐Processor
Procedure/Working
6. The light sensor gives an input to the microprocessor
which then gives an output to determine, if the
photographer has selected the shutter controlled rather
than aperture controlled mode, the time for which the
shutter will be opened.
7. When the photograph has been taken, the microprocessor
gives an output signal to the motor drive to advance the
film ready for the next photograph.

The automatic Camera

An Example of Micro‐Processor
Steps of the program for the automatic
camera
Begin if battery check input OK then continue
otherwise stop

Loop Read input from range sensor Æ calculate lens

movement Æ output signal to lens position drive Æ input data
from lens position encoder (a network or system in which only
one input is excited at a time and each input produces a
combination of outputs) Æ compare calculated output with
actual output Æ stop output when lens in correct position Æ
send in-focus signal to viewfinder display etc.

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The Automatic Camera

The engine Management System

An Example of Micro‐Controller

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The Engine Management System

An Example of Micro‐Controller
Steps of Events
1. For ignition timing, the crankshaft drives a distributor which makes
electrical contacts for each spark plug in turn and a timing wheel.
2. This timing wheel generates pulses to indicate the crankshaft
position.
3. The microprocessor then adjusts the timing at which high voltage
pulses are sent to the distributor so they occur at the 'right'
moments off time.
i
4. To control the amount of air-fuel mixture entering a cylinder during
the intake strokes, the microprocessor varies the time for which a
solenoid is activated to open the intake valve on the basis of inputs
received of the engine temperature and the throttle position.

The engine management system

An Example of Micro‐Controller
Steps of Events
5. The amount of fuel to
be injected into the air
stream can be determined by
an input from a sensor of the
mass rate of air flow, or
computed from other
measurements, and the
microprocessor then gives
an output to control a fuel
injection valve.

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The engine management system

An Example of Micro‐Controller
Steps of Events
5. The amount of fuel to
be injected into the air
stream can be determined by
an input from a sensor of the
mass rate of air flow, or
computed from other
measurements, and the
microprocessor then gives
an output to control a fuel
injection valve.

LEVELS OF AUTOMATIONS
The concept of Automated system can be applied to various levels of factory operations.

Level Description/Example

5 Enterprise Level Corporate information system

4 Plant Level Production system

3 Cell or system Level Group of Machines

2 M/c Level Individual Machines

1 Drive Level Sensors, Actuators, etc

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LEVELS OF AUTOMATIONS
1. DRIVE LEVEL: This is the lowest level in automation
hierarchy. It includes sensors, actuators and other hardware
components that comprise machine level.
2. MACHINE LEVEL: Control function at this level
includes performing the sequence of steps in program of
instruction in correct order.
3. CELL OR SYSTEM LEVEL: This level operates under
program instruction from plant level. Functions include part
dispatching and machine loading, coordination among machines
etc.
4. PLANT LEVEL: This is the pproduction level. It receives
instructions from the corporate information system and translate
them into operational plans for production e.g. order processing,
process planning, inventory control, shop floor control etc.
5. ENTERPRISE LEVEL: It is concerned with all of the
functions necessary to manage the company e.g. marketing and
sales, accounting, design, aggregate planning etc. are in this level.

Aggregate Planning
It is an operational activity which does an aggregate plan for the
production process, in advance of 2 to 18 months, to give an
idea to management as to what quantity of materials and other
resources are to be
b procured d andd when,
h so that
h the
h totall cost off
operations of the organization is kept to the minimum over that
period.
Aggregate planning has certain pre‐required inputs. They include:
1. Information about the resources and the facilities available.
2. Demand forecast for the period for which the planning has to
be done.
done
3. Cost of various alternatives and resources. This includes cost of
holding inventory, ordering cost, cost of production through
various production alternatives like subcontracting,
backordering and overtime.
4. Organizational policies regarding the usage of above
alternatives.

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Backorder & Forward

Backorder is a distribution term that refers to
th status
the t t off items
it on a purchase
h order
d ini the
th
event that some or all of the inventory required
to fulfill the order is out of stock. This differs
from a forward order where stock is available
but delivery is postponed for another reason.

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