Module2 1 - Mecha Toolbox I

MECHATRONIC PRODUCT DEVELOPMENT
Systems and
components
(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
Product Innov@tion -- Maschinenbau 1

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 product
n
assurance of properties
t io
sys
gra
inte
te m
tem
des
Control Simulation 3D Visualization

sys
ig
n
domain-specific design
Control programming
Actors Sensors E-CAD
Basic System M-CAD
modeling and model analysis

Mechatronic system
Control technology
Control
Electro mechanical
Actors Sensors Border
Basic System
Mechanical design
Material Energy Information
requirements product
n
assurance of properties
io
grat
syst
inte
em
em
desi
Control Simulation 3D Visualization

syst
gn
domain-specific design
Control programming
Actors Sensors E-CAD
Basic System M-CAD
modeling and model analysis
Mechatronic system overview
Connection
possibilities
Control types
Types and
Types and
signals Control signals
Actuators Sensors
Basic system
Cycle time
Physical
connections

Signal flow of electronic controls
Control
signal adjustment
signal processing signal adjustment
(ampilifier)
Field communication
Output level Signal Input level

flow
Actors Sensors
Basic system
User
Connection
possibilities
Control types
Types and
Types and
Actuators Sensors
Basic system
Cycle time
Physical
connections

Definition “control”
— Control:
According to DIN 19237 the control serves for the influence of

the output variables of a system by one or more input
parameters due to the system specific behavior.
[G. Phal, W. Beitz, J. Feldhusen, K.H. Grote 2003, S. 571]
First control system / liquid level control

First control systems
— Liquid-level Control:
— greece 300 B.C.: water clock; time measurement by
trickling water constantly into a container -> similar to
water level control in flush toilets
— Steam pressure control (1681)

— Denis Papin‘s 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 differential
equation
— Mechnical control
— Cam discs
Mechanical control automatic lathe
weck

Sample of a cam disc
x X=f(φ)
Mechanical
angle input φ Output function f(φ)
Transfer element
Usages of cam discs
— Date indication in watches

(hours and minutes cam shafts from 1927)
— Cam shaft in engines:
— Cam shafts in textile machines:

Electronic cam disc

Mechanical
cam disc
Control Output function f(t)

Servo cam
disc
— The control takes over the functionality of the mechanical

transfer 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!
Electronic Controls

Overview of control types
Elektrical Controls
(Elektrische Steuerungen)
Logic control Sequential control

(Verknüpfungs- (Ablaufsteuerung)
Steuerung)
time bounded process bounded

Sequential circuit Combinatorial circuit (zeitgeführt) (prozessgeführt)
(Schaltwerke) (Schaltnetze)
Cyclic signal Event oriented signal

processing (zyklische processing (ereignisorientierte
Signalverarbeitung) Signalverarbeitung)
Sample of the different control types
Control type Description Application area
Logic control Input signals are assigned to Dredger control

output signals by boolean (Bagger), crane
(Verknüpfungs- logic without being control, simple
Steuerung) constrained for a sequential gate controls,
processing overpressure/
[DIN 19237] overheat controls
— Logic controls are the predecessors of sequential controls
— They are still used for simple applications, e.g. gate controls or
in cranes or dregger, where the human take of over the “control”
of the sequences to be executed

Overview of control types
Elektrical Controls
(Elektrische Steuerungen)
Logic control Sequential control

(Verknüpfungs- (Ablaufsteuerung)
Steuerung)
time bounded process bounded

Sequential circuit Combinatorial circuit (zeitgeführt) (prozessgeführt)
(Schaltwerke) (Schaltnetze)
Cyclic signal Event oriented signal

processing (zyklische processing (ereignisorientierte
Signalverarbeitung) Signalverarbeitung)
Sample of the different control types
Control type Description Application area
Sequential Control with forced Automization;

control sequential processing where CNC machines,
the switch from on step to robotics
(Ablauf- the following is dependent on
steuerung) the defined switching
conditions
[Deutsche Elektronische Kommission]

Types of sequential controls
Control Characteristics Applications Cycle Provider

type time
CNC Interpolated path Standard 0.01-1ms Siemens

generation/ tracking; machines (Sinumerik);
standard UI Fanuc (series
30i/300i);
NUM
PLC Control of analog/ Automation, 1-100ms Simatic;
digital i/o’s handling Rockwell, B&R;
Beckhoff
Motion Virtual upright shaft Automation, 0.01-10ms Simotion; B&R

control (Königs-welle) special
realisation; virtual machines
cam disc
(Kurvenscheiben)
embedded Usage of standard Communicati 0.01- Fanuc;
components (PC); on; 100ms
Miniaturisation
Control design
— Typical components of a PLC/ CNC/ embedded Control (CPU,

RAM, E/A,…)
PLC
CPU Memory
RAM
Processor
In-/output
Interface
Bus system
Interfaces Bus

Connection
possibilities
Control types
Types and
Types and
Actuators Sensors
Basic system
Cycle time
Physical
connections
Definition “sensor”
— Sensor: A sensor converts a state variable of a technical process

of a quality which is not suitable as a signal into a signal which
can be transmitted, further processed and registered. [VDI 2206
2004]
— Converts a state variable of the basic system, into an information signal to

the control.

Classification of sensors
Sensor base types Application areas
Mechanical sensors Position, displacement, velocity, acceleration, vibration, stress

and strain, force, torque, pressure, surface topography
roughness, etc.
Electrical and magnetic Voltage, current, resistance, capacitance, inductance,

sensors magnetic, radiation
Acoustic and flow sensors Sound intensity (pressure), viscosity, flow rate frequency, …
Chemical and biological pH, enzymes, ions, gases, concentration, humidity, biological,
sensors frequency shift or Doppler
Optical sensors Intensity, wavelength, phase, vision, interference
Thermal sensors Temperature, infrared radiation image, etc.
Examples of sensors
Mechanical: Mechanical: Mechanical:

displacement accelleration pressure
Chemical: Optical: Electrical: Electrical:

concentration intensity inductance resistance

Signal transformation in sensors
Control
InPro 8400 MT Trübheitssensor
Electrical
Sensor
voltage/
current
Physical reaction
Process
characteristics
Base System
state variables
Complex sensors
— Complex sensors are combined sensors that contain different

base 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

Connection
possibilities
Control types
Types and
Types and
Actuators Sensors
Basic system
Cycle time
Physical
connections
Definition “actor”
— Actor/Actuator: Converts an information signal from the control,

into energy acting on the basic system.
[Bathelt, Jönsson, Dierssen 2005]

Classification of sensors and actuators
Actor types Application areas
Force / movement actors Synchron (AC/DC) drive, asynchron drive, linear drive,
relay, piezo-electric drive, pneumatic drive, hydraulic drive
Heat actors Resistance heating
Acoustic actors Speaker
Optical actors Displays, LEDs
Example of actors
Movement: Torque: Movement:

electromagnetic electromagnetic pneumatic
Light: Current: Sound:

LED voltage electromagnetic

Signal flow between controls - actors
Primary signal Control
Additional Low power

energy e.g. +/-10V_24V
Amplifier
Secondary
signal
High power
e.g. 220/380V; 0.1-300 A
Actor
Energy
Base System
Signal flow between controls - actors
Primary signal Secondary

signal
+/-10V_24V
Voltage (analog) current
information (digital) 0.1-300 A

torque
Control
Voltage (analog) pressure
information (digital) 0.01-300 bar
movement
Voltage Current/voltage
information (digital) 0.1- 10 A

heat

Connection
possibilities
Control types
Types and
Types and
Actuators Sensors
Basic system
Cycle time
Physical
connections
Definition “basic system”
— Basic System:
Basis of the mechatronic system consisting of ordered and linked

elements that have an interface to the environment by defined
input and output parameters that influence the system.

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

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MECHATRONIC PRODUCT DEVELOPMENT

Product Innov@tion -- Maschinenbau 1

— 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

Control Simulation 3D Visualization

modeling and model analysis

Product Innov@tion -- Maschinenbau 2

Material Energy Information

Control Simulation 3D Visualization

modeling and model analysis

Mechatronic system overview

Product Innov@tion -- Maschinenbau 3

Signal flow of electronic controls

Output level Signal Input level

Mechatronic system overview

Product Innov@tion -- Maschinenbau 4

According to DIN 19237 the control serves for the influence of

First control system / liquid level control

Product Innov@tion -- Maschinenbau 5

First control systems

— Steam pressure control (1681)

— Speed control (1745)

— Stability, Stabilization and Steering (1868)

Mechanical control automatic lathe

Product Innov@tion -- Maschinenbau 6

Sample of a cam disc

Usages of cam discs

— Date indication in watches

— Cam shaft in engines:

— Cam shafts in textile machines:

Product Innov@tion -- Maschinenbau 7

Electronic cam disc

Control Output function f(t)

— The control takes over the functionality of the mechanical

— 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!

Product Innov@tion -- Maschinenbau 8

Overview of control types

Logic control Sequential control

time bounded process bounded

Cyclic signal Event oriented signal

Sample of the different control types

Control type Description Application area

Logic control Input signals are assigned to Dredger control

— Logic controls are the predecessors of sequential controls

Product Innov@tion -- Maschinenbau 9

Overview of control types

Logic control Sequential control

time bounded process bounded

Cyclic signal Event oriented signal

Sample of the different control types

Control type Description Application area

Sequential Control with forced Automization;

Product Innov@tion -- Maschinenbau 10

Types of sequential controls

Control Characteristics Applications Cycle Provider

CNC Interpolated path Standard 0.01-1ms Siemens

Motion Virtual upright shaft Automation, 0.01-10ms Simotion; B&R

— Typical components of a PLC/ CNC/ embedded Control (CPU,

Product Innov@tion -- Maschinenbau 11