module2 1 - mecha toolbox i

7/31/2019 Module2 1 - Mecha Toolbox I

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MECHATRONIC PRODUCT DEVELOPMENT

Product Innov@tion -- Maschinenbau 1

Systems andcomponents(mechatronic toolbox)Part 1

Stefan Dierssen

Content of module 2

Part 1:

System Overview

Control types

Peripherals (sensors/ actors)

Basic systems

Part 2:

Control programming (overview)

NC Controls

Field communication

Cycle time


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Objectives

Know the major elements of a mechatronic system

Overview of control types and their application areas

Functionality and characteristics of sensors and actuators

Definition of base systems

Leadslide

requirements

assurance of propertiessy

stemdesign

syste

minte

grati

on

product

modeling and model analysis

domain-specific design

E-CAD

programming

M-CAD

Control Simulation 3D Visualization

Control

Basic System

SensorsActors


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Mechatronic system

requirements

assurance ofpropertiessyste

mdesign

s y s t e

m i n t e

g r a t i o n

product

modelingand modelanalysis

domain-specificdesign

E-CAD

programming

M-CAD

C o nt r ol S i mu l at i on 3 D V is u al i za t io n

Control

Basic System

SensorsActors

InformationMaterial Energy

Electro mechanical

Border

Mechanical design

Control technology

Control

Basic System

SensorsActors

Mechatronic system overview

Control

Basic system

SensorsActuators

Control types

Connection

possibilities

Types and

signals

Cycle time

Types and

signals

Physical

connections


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Basic system

Signal flow of electronic controls

Field communication

SensorsActors

User

Output level Signal

flow

Input level

Control

signal processingsignal adjustment

(ampilifier)signal adjustment


Control

Basic system

SensorsActuators

Control types

Connection

possibilities

Types and

signals

Cycle time

Types and

signals

Physical

connections


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Definition control

Control:

According to DIN 19237 the control serves for the influence ofthe output variables of a system by one or more inputparameters due to the system specific behavior.[G. Phal, W. Beitz, J. Feldhusen, K.H. Grote 2003, S. 571]

First control system / liquid level control


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First control systems

Liquid-level Control:

greece 300 B.C.: water clock; time measurement bytrickling water constantly into a container -> similar towater level control in flush toilets

Steam pressure control (1681)

Denis Papins safty valve: Weighting the valve top

Speed control (1745)

Pitching blades of a windmill

Stability, Stabilization and Steering (1868)

James Clerk Maxwell published stability criterion for third-order system based on the coefficients of the differentialequation

Mechnical control

Cam discs

Mechanical control automatic lathe

weck


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Sample of a cam disc

angle input Mechanical

Transfer elementOutput function f()

X=f()x

Usages of cam discs

Date indication in watches(hours and minutes cam shafts from 1927)

Cam shaft in engines:

Cam shafts in textile machines:


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Electronic cam disc

The control takes over the functionality of the mechanicaltransfer element

Desired output function is directly executed by a servo drive

Highly dynamic drives and mechanical base systems are needed!

Synchronisation of multiple drives is a very important issue!

Control Output function f(t)

Mechanical

cam disc

Servo cam

disc

Electronic Controls


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Overview of control types

Elektrical Controls

(Elektrische Steuerungen)

Logic control

(Verknpfungs-

Steuerung)

Sequential control

(Ablaufsteuerung)

time bounded

(zeitgefhrt)

process bounded

(prozessgefhrt)

Cyclic signal

processing (zyklische

Signalverarbeitung)

Event oriented signal

processing (ereignisorientierte

Signalverarbeitung)

Sequential circuit

(Schaltwerke)

Combinatorial circuit

(Schaltnetze)

Sample of the different control types

Dredger control(Bagger), cranecontrol, simplegate controls,overpressure/overheat controls

Input signals are assigned tooutput signals by booleanlogic without beingconstrained for a sequentialprocessing[DIN 19237]

Logic control

(Verknpfungs-Steuerung)

Application areaDescriptionControl type

Logic controls are the predecessors of sequential controls

They are still used for simple applications, e.g. gate controls orin cranes or dregger, where the human take of over the controlof the sequences to be executed


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Overview of control types

Elektrical Controls

(Elektrische Steuerungen)

Logic control

(Verknpfungs-

Steuerung)

Sequential control

(Ablaufsteuerung)

time bounded

(zeitgefhrt)

process bounded

(prozessgefhrt)

Cyclic signal

processing (zyklische

Signalverarbeitung)

Event oriented signal

processing (ereignisorientierte

Signalverarbeitung)

Sequential circuit

(Schaltwerke)

Combinatorial circuit

(Schaltnetze)

Sample of the different control types

Automization;CNC machines,robotics

Control with forcedsequential processing wherethe switch from on step tothe following is dependent onthe defined switchingconditions[Deutsche Elektronische Kommission]

Sequentialcontrol

(Ablauf-steuerung)

Application areaDescriptionControl type


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Types of sequential controls

ProviderCycletime

ApplicationsCharacteristicsControltype

Fanuc;0.01-100ms

Communication;

Usage of standardcomponents (PC);Miniaturisation

embedded

Simotion; B&R0.01-10msAutomation,specialmachines

Virtual upright shaft(Knigs-welle)realisation; virtualcam disc(Kurvenscheiben)

Motioncontrol

Simatic;Rockwell, B&R;Beckhoff

1-100msAutomation,handling

Control of analog/digital i/os

PLC

Siemens(Sinumerik);Fanuc (series

30i/300i);NUM

0.01-1msStandardmachines

Interpolated pathgeneration/ tracking;standard UI

CNC

PLC

In-/output

CPU Memory

Interface

Bus system

Control design

Typical components of a PLC/ CNC/ embedded Control (CPU,RAM, E/A,)

Processor

Bus

RAM

Interfaces


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Control

Basic system

SensorsActuators

Control types

Connection

possibilities

Types andsignals

Cycle time

Types and

signals

Physical

connections

Definition sensor

Sensor: A sensor converts a state variable of a technical processof a quality which is not suitable as a signal into a signal whichcan be transmitted, further processed and registered. [VDI 22062004]

Converts a state variable of the basic system, into an information signal tothe control.


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Classification of sensors

Application areasSensor base types

Temperature, infrared radiation image, etc.Thermal sensors

Intensity, wavelength, phase, vision, interferenceOptical sensors

pH, enzymes, ions, gases, concentration, humidity, biological,frequency shift or Doppler

Chemical and biologicalsensors

Sound intensity (pressure), viscosity, flow rate frequency, Acoustic and flow sensors

Voltage, current, resistance, capacitance, inductance,

magnetic, radiation

Electrical and magnetic

sensors

Position, displacement, velocity, acceleration, vibration, stressand strain, force, torque, pressure, surface topographyroughness, etc.

Mechanical sensors

Examples of sensors

Mechanical:

displacement

Mechanical:

accelleration

Chemical:

concentration

Electrical:

resistance

Mechanical:

pressure

Optical:

intensity

Electrical:

inductance


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Signal transformation in sensors

Physical reaction

Process

characteristics

Electrical

voltage/current

InPro 8400 MT Trbheitssensor

Control

Base System

state variables

Sensor

Complex sensors

Complex sensors are combined sensors that contain differentbase sensor types (e.g. vision systems; sensors including

calibration sensors,)

Structured light principle:- A laser projects light into a scene in a

known direction

- The intersection of the laser with objects is

observed by a video camera

- By triangulation the distance of the object

can be measured


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Control

Basic system

SensorsActuators

Control types

Connection

possibilities

Types andsignals

Cycle time

Types and

signals

Physical

connections

Definition actor

Actor/Actuator: Converts an information signal from the control,into energy acting on the basic system.

[Bathelt, Jnsson, Dierssen 2005]


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Classification of sensors and actuators

Application areasActor types

Displays, LEDsOptical actors

SpeakerAcoustic actors

Resistance heatingHeat actors

Synchron (AC/DC) drive, asynchron drive, linear drive,

relay, piezo-electric drive, pneumatic drive, hydraulic drive

Force / movement actors

Example of actors

Movement:

electromagnetic

Torque:

electromagnetic

Movement:

pneumatic

Light:LED

Sound:electromagnetic

Current:voltage


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Signal flow between controls - actors

Primary signal

Secondary

signal

Low power

e.g. +/-10V_24V

High power

e.g. 220/380V; 0.1-300 A

Control

Amplifier

Actor

Base System

Energy

Additional

energy

Signal flow between controls - actors

Primary signal

Voltage

Voltage (analog)

information (digital)


Secondary

signal

pressure

current

Current/voltage

movement

torque

Voltage (analog)


+/-10V_24V

0.1-300 A

0.01-300 bar

0.1- 10 A

Control

heat


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Control

Basic system

SensorsActuators

Control types

Connection

possibilities

Types andsignals

Cycle time

Types and

signals

Physical

connections

Definition basic system

Basic System:

Basis of the mechatronic system consisting of ordered and linkedelements that have an interface to the environment by definedinput and output parameters that influence the system.


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Objectives

Know the major elements of a mechatronic system

Overview of control types and their application areas

Functionality and characteristics of sensors and actuators

Definition of base systems

module2 1 - mecha toolbox i

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