MOTION & AUTOMATION

ME 4176

Dr Ng
Nguyen
y Hongg Q Quangg
Department of Industrial Automation

Contact

• Nguyen Hong Quang:

- Lecturer at Industrial Automation Department
- E-mail: quangnh@mail.hut.edu.vn

• Nguyen Thi Hong Minh

- E-mail: nguyenthihongminh@mail.hut.edu.vn

- Lecturer at Mechanical Engineering Faculty

1
 What I expect from you

• Lectures
- Turn up (hence the attendance marks)
- Ask (sensible) questions as much as you like
- Take an interest in the material being presented
• Labs :
- Work on questions before labs

Course Objectives

• Focus on practices
• Learn how some of the common motion
control application can be solved

• To provide a general introduction to

mechatronic principles:
- Systems
- Control
-Computing
-- Sensors
- Actuators

2
 Course Outcomes

• A broad appreciation of mechatronics for

both mechatronic and mechanical engineers
• An understanding of the main components
of a mechatronic system and how they fit
together
• A knowledge of what is ‘out there’ and what
might be possible

Schedule of Events
Week Contents Notes
1 Introduction to Mechatronics
2 Mechanical actuation systems
3 Electrical atuation systems
4 Programmable logic controllers
5 PLC Input/output systems
6 Introduction to Mitsubishi PLC
7 System Modelling and Control
8 Digtal PID and tuning
9 Case study: Concrete Mixer Industry
10 Design Process
11 Case study: Segway
12 Questions and Answers

3
 References
 Mechatronics – an Introduction by Robert H.
Bishop
 Mechatronics Handbook, edited by the same
authour
 Programmable Controllers: Theory and
Implementation by L.A. Bryan, E.A. Bryan

Examination
• Attendance
- Worth 10% - I’ll pass around a list to
be initialled during the lectures

• Lab excersies
- PLC control Exercise - Worth 20%

• Final examination – Worth 70%

4
 Questions
 Distinguished between
 Micro-processor
p
 Micro-computer
 Micro-controllers
 Definition of PWM ?
 What is main loop of C embedded program ?
 Some examples of
 Opened-loop control
 Closed-loop control
 Pneumatic and Hydraulic

What is Mechatronics?
•An interdisciplinary
area of
p
specialization Computing
involving the
simultaneous
application of
mechanical,
electrical, control Electrical Control
and computer
engineering
principles together
with computer Mechanical
software in
designing useful
systems

5
 Mechatronic System components
 Mechanical – mechanism design and understanding of
physical characteristics of system
 Actuators – act on the environment
 Sensors – sense some aspect of the environment
 Electronics – provide interfaces to sensors and actuators
 Computing – processing of information
 Control – provide actuator commands in response to
particular
ti l system
t state
t t
 Systems Design – design is an important part of
Mechatronic Engineering

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What courses relate to Mechatronics?

• Mechanical • Control
- Statics - Systems Control
- Advanced
Ad d Dynamics
D i - Advanced
Ad d Control
C t l
- Dynamics of Vibration • Computing
- Mechanical Design - Introduction to C
• Electrical Programming *
- Introduction to Electical - Real Time Systems
Engineering
- Digital Design * • Mechatronics
M h t i
- Electronics * - Intro. To Mechatronics
- Power Electronics *

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 Mechatronic Components
Decision Process
• System Models
• Control

Time Scales
Sensors Degree of Flexibility
Actuators
Complexity of
Decisions Costs

REAL WORLD

Model of a Mechatronic System

Desired System
Performance
Control

Noise Signal Capture Actuators

S
Sensors Mechanical
Disturbances
System

Environment

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 Examples : Hard Drive

• A computer disk drive is

another example of a
rotary mechatronic
system
• Requires
-Accurate positioning of
the magnetic read head
- Precise control of media
speed
- Extraction of digital data
from magnetic media

Grand Challenge
 Control of vehicle
performed using
onboard computer
 Sensors include larer,
radar, sonar, vision,
inertial, compass and
DGPS
 Distance is more than
100km on large
desert

16

8
 Data structure

17

Autonomous Flight Control

Systems
Rudder position
Forward sensors
(radar, vision, laser)

Elevon position
Engine RPM

9
 Flight Monitor

Stefan Williams 1540 Introduction To Mechatronics 50

The traditional mechanical

control

Watt’s flyball governor.

20

10
A traditional Electro-Mechanical design

Analog I/O
Timing

A Mechatronic design

Micro Processor

Amp.

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 The Motor Control Loop

Control Micro Processor

Sensing

Amp.

M Load
Actuation

Actuators:Types

• DC Servos
• AC Servos
• Stepper Motors
• Piezo
• Pneumatic
• Hydraulic

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 Actuators: Main Issues

• Power
• Speed
• Torque/Force
• Speed of response
• Ripple/noise
• Resolution
R l ti
• Friction/backlash

Sensors

• Physical Transduction Methods

• Signal Conditioning
• Signal Conversion

13
 Sensors: Physical
Transduction Methods
• Mechanical
• Electro-Magnetic
g
• Optical
•Thermal
• Acoustic

Position sensor

28

14
 Sensors: Signal Conditioning

• Amplification
p
• Noise suppression
• Filtering
• Shock and environment

Smart Sensors: Conversion

• Analogue-digital
A l di it l conversion
i (sampling)
( li )
• Signal frequency (sample rate)
• Aliasing
• Memory and processing cycles
• Signal processing algorithms

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 The Decision Process

• Analogue Electronic
Systems
• Programmable Logic Controller (PLC)
• Micro Controller
• Digital Computer

Pay-Offs

• Complexity
p y
• Speed
• Reliability
• Cost
• Flexibility

Stefan Williams 1540 Introduction To Mechatronics 30

16
 Op-amp computing

33

Micro-controller based system

34

17
 PLC system

35

System Modelling With

Block Diagrams

• A block diagram describes system structure

• A block diagram describes the mathematics
used to model the system
• A block diagram can be used to understand
the system both physically and
mathematically

Stefan Williams 1540 Introduction To Mechatronics 31

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 System Modelling With
Block Diagrams

Load
Disturbance
Desired Actual
Velocity + Velocity
Controller, Motor/Load
+ Amplifier Dynamics +
-

Voltages ?
Measured
Velocity Velocity

Measurement

System Modelling With

Block Diagrams

yn
+
xd u dy 1 y
u= K (xd − xm ) + y= x
+ dx T +
-
xm
ya
xm = Ayb + B

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 System Modelling With
Block Diagrams

Input Transfer Output

Function

A “gain”
“ i ”
Differential
Equation Logic
Condition Look-up
Table

A State Machine Analysis

• A conceptual
p understandingg of
procedure
• A method for structuring system and
software
• Well defined system states and
transfer events

Stefan Williams 1540 Introduction To Mechatronics 35

20
 System Modelling With
State Machines

Power
Power down
Fail
up
Power off
Fail Signal
Power
on
Signal
Initialise Run
Data Ready

Data Base

The Run State

Fail Fail
Ready

Done Fill

Stop
Wash
Spin
Rinse

Empty

21
 Flow Chart : Fill State
Start
• Describes flow of
operation
p within a Open
p Valve
particular state
• Used to represent Check Level
Overflow
sequence of No
actions to be taken Fill Achieved?
Timeout
Yes
Open Valve
Fail
Stop

Overall Systems Behaviour

• System Engineering
• Control Theory

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 Systems Behaviour I

• Stability:
- Will it oscillate or blow up in some unpredictable way ?
- Is it naturally stable or does it require active control ? •
Robustness:
- Will it be sensitive to small changes in system or environment
parameters ?
- What about uncertainty and signal noise ? - If I hit it,
it
does it fall over ?

Systems Behaviour II

• Speed of Response
- Will it react sufficiently quickly on request ? - Can it respond to
“high frequency change” in desired position etc (Bandwidth) ?

• Energy Efficiency
- Does it do what it is supposed to do using a minimum amount of
energy ?
- Is there enough actuator power to drive the system ?

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 System Behaviour III

• Safety
-Will it carry on working if something fails ?
- Will it fail but fail in a known way ?
- Software, actuator, sensor failures
- Standards, proofs, test programme.

• Economics
-Overall cost in market
-- Size, weight, noise
-- Does it look good ?!!

Case study
 The concrete mixer in Vietnam
 The Segway made by HUT
 The turbine governor system

48

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 The concrete mixer – PLC system

49

The Segway
Accelerometer Gyro

Bảng điều khiển

MASTER CAN SLAVER

dsPIC30F dsPIC30F

Phản Phản
hồi hồi
dòng MOSFET Driver dòng
MOSFET Driver
điện Bộ 1 điện
Bộ 2

Bộ nghịch lưu Bộ nghịch lưu

dùng dùng
MOSFET MOSFET

Cảm biến HALL BLDC 1 BLDC 2 Cảm biến HALL

50

25
 Digital turbine governor

51

Mechatronics approach in design

Hardware in the loop (HIL)

52

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