Lecture

Open & Closed Loop

Engr. Dr. Nazeer Ahmed Anjum
 Todays Topic:
• Elements of Closed Loop
• Mechatronics Design Process
• Advanced Approaches in Mechatronics
• Intelligent Control System
• Model Based Monitoring System
• Control variables for maintaining Temperature
• Control variables for maintaining Water level
 Elements of Closed Loop
Reference
Value (+)
Control Correction
Process
Unit Unit
Error
Signal

Measuring
Device
Measured Value Feed Back Controlled
(-) Variable
 Comparison Element
Reference signal = +ve (That is adding or set value)
Measured value (Signal) = -ve (at out put)
Error signal = Reference Value – Measured Value
The summed value is fed to the segmented circle called
comparison element
All I/P are added
-ve Feedback: when it is subtracted from the I/P or
reference value
+ve Feedback: when it is added to the reference value
 Control Element
It decides when action has to be taken after receiving an
error signal.

Correction Element
It produces a change in the process to correct or
change the controlled condition. In example of
heating the room, the switch is the key element which
‘ON’ a heater & so increases the temp of the process
or a valve which opens & allows more liquid to enter.
Switch or Actuator is the element used as a correction
unit.
 Process Element
The process is, what is being controlled. It may be a
room in a house with its temp being controlled or a tank
of water with its level being controlled, or a milling,
drilling or shaping process.

Measurement Element
It produces a signal related to the variable condition
of the process that is being controlled. For heating the
house ‘thermometer’ is the measurement element.
 Mechatronics Design Process
The Mechatronic design methodology is concerned not
only with producing high quality products but with
maintaining them as well, an area referred to as life cycle
design. The following are the important life-cycle
factors:
Delivery: Time, cost, and medium.
Reliability: Failure rate, materials, and tolerances.
Maintainability: Modular design (Design of components that can
.
be assembled in a variety of ways to meet individual consumer needs)
Serviceability: On board diagnostics; prognostics, and
modular design.
Upgradeability: Future compatibility with current designs.
Disposability: Recycling and disposal of hazardous
materials
 Mechatronics Design Process
In the Mechatronic design approach, life cycle factors
are included during the product design stages, resulting
in products that are designed from conception to
retirement.
Mechatronics Design Process consists of three phases:
1. Modeling and Simulation
2. Prototyping and
3. Development
Modeling/Simulation

Recognition of Prototyping Development/Life Cycle

the Need

Conceptual Design &

Functional Specification Hardware in the Loop Development of
Simulation Embedded Software
First Principle Modular
Mathematical Modeling Design Life Cycle
Optimization Optimization
Sensor & Actuator
Selection

Detailed Modular
Mathematical Modeling

Control System Design

Design Optimization
 Mechatronics Design Process
Modeling: Block diagram or visual interface for
creating understandable models of physical or abstract
phenomenon. The ability to summarize complexity and
maintain several levels of sub-model complexity is
useful.
Simulation: Numerical methods for solving models
containing differential, discrete, hybrid, partial, and
nonlinear as well as linear equations. Must have a real-
time operation and be capable of executing faster.
Project Management: Database for maintaining project
information and sub-models for eventual reuse.
Design: Numerical methods for constrained
optimization of performance functions based on model
parameters and signals.
 Mechatronics Design Process
Analysis: Numerical methods for frequency domain, time
domain, and complex domain design.
Real-Time Interface: A plug-in card is used to replace
part of the model with actual hardware by interfacing to it
with actuators and sensors. This is called a hardware-in­
the-loop simulation or rapid prototyping and must be
executed in real time.
Code Generator: To produce efficient high-level source
code from the block diagram or visual modeling
interface. The control code will be compiled and used on
the embedded processor. The C language is usually used.
Embedded Processor Interface: It resides in the final
product, and this feature provides communication
between it and the computer-aided prototyping
environment.
 Advanced Approaches in Mechatronics
Recent developments in Mechatronics are also creating
opportunities in intelligent manufacturing. In order to produce
high-quality products at low life cycle costs, many
manufacturing plants have been reducing their workforce. As a
result, the reduced workforce has to cope with additional tasks
and responsibilities, and there is a broader area of control for
plant management. This trend has significantly influenced the
Mechatronics field, especially in the area of sensor-based
manufacturing. It has created opportunities for the use of
intelligent autonomous inspection systems as well as
intelligent decision-making systems that perform tasks
automatically, without human intervention.
In an intelligent inspection system, real-time control is
introduced during the process of manufacturing to provide an
increase in machining quality and productivity.
It ensures a quality standard for all products with minimal
sampling error. This method reduces the need for post-process
inspection.
Intelligent Supervisory Control System in Mechatronics
Manufacturing processes depend on many
layers of control sequences that are
separated by different levels in their time Plant
PlantControl
Control
scales.
Servo control Level (lowest level):
The motion of a cutting tool relative to a Shop
ShopFloor
FloorControl
Control
workpiece, such as position or velocity, is
controlled.
Supervisory
SupervisoryControl
Control
Process Control Level (Second
level): In this process variables such as
cutting forces or tool wear are controlled.
Control level strategies are aimed at Process
ProcessControl
Control
compensating for factors not explicitly
considered in the design of the servo and
process level controllers. For example, Servo
workpiece geometry, present in the ServoControl
Control
computer-aided design system, may be
used to determine the reference values of
process variables.
Intelligent Supervisory Control System in Mechatronics
Supervisory Level (Third level): It
monitors product characteristic
variables, such as part dimension or Plant
surface roughness, and makes PlantControl
Control
adjustments by modifying commands
sent to the process and servo levels.
Shop Floor and Plant Control Level Shop
ShopFloor
FloorControl
Control
(Last level):
Finally, all of this information can be Supervisory
SupervisoryControl
Control
used to achieve on-line optimization of
the machining process at the shop floor
and plant control level. Process
ProcessControl
Control
Model-based monitoring using
intelligent sensors is an important
technology holding much promise for Servo
ServoControl
Control
improving manufacturing productivity
and quality.
 Model Based Monitoring System
Input Disturbances Decision Making

Manufacturing Process Models,

Process Algorithms
Sensing and
Measurement

Process Adjustments
Controller Monitoring
 Traditional Element for Controlling the
Room Temperature
Controlled Variable The room Temp.
Reference value The required room Temp.
Comparison Element A person comparing the
measured value with the
Error signal required value of temp.
The difference b/w the
Control Unit measured & required
Correction unit Temp.
Process The person
Measuring device The switch
Heating by fire
Automatic Control of Water Level (By
Mechanical Elements)
Flap

Water In
Float
Ball

Pivot

Lever
Water
out
 Automatic Control of Water Level (By
Mechanical Elements)
Controlled Variable Water level in tank
Initial setting of the float &
Reference value lever position
Comparison Element The lever
The difference b/w actual &
Error signal initial settings of lever
positions
Control Unit
The pivoted lever
Correction unit
The flap opening or closing
Process the water supply
Water level in Tank
Measuring device Floating ball & lever
 How we can change the Mechanical
system for maintaining the water level
into a Mechatronics system, list the
Mechatronics elements
 List of Equipments
For electronic Control  Level sensor 
supplying electrical signal  after suitable
conditioning or amplifying fed to comparator 
comparing with set value.
Error Signal  to the controller
Then correction element adjust the difference.
After suitable signal conditioning, used to
control the movement of an actuator in a flow
control valve. Then it determine the amount of
water fed into the tank.