Mechatronic Systems and Process Automation: Model-Driven Approach and Practical Design Guidelines

468 Pages·2018·56.91 MB·English

by  Patrick O.J. Kaltjob

Mechatronic Systems and
Process Automation
Model-Driven Approach and
Practical Design Guidelines
http://taylorandfrancis.com
Mechatronic Systems and
Process Automation
Model-Driven Approach and
Practical Design Guidelines
Patrick Kaltjob
CRC Press
Taylor & Francis Group
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Boca Raton, FL 33487-2742
© 2018 by Patrick Kaltjob
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Contents
Preface ...................................................................................................................xiii
Author ...................................................................................................................xix
1. Introduction to Mechatronic Systems and Process Automation ..........1
1.1 Introduction ...........................................................................................1
1.2 Definitions and Classifications ...........................................................1
1.3 Generic Automation System Architecture and Components .........5
1.3.1 Data Processing and Computing Unit ..................................6
1.3.2 Data Acquisition and Transmission Unit .............................6
1.3.3 Electrical-Driven Actuating Unit ...........................................7
1.3.4 Measuring and Detecting Unit ..............................................7
1.3.5 Signal-Conditioning Unit .......................................................7
1.4 Examples of Product and Industrial Process Automation ..............7
1.5 Generic Automation System Objectives and Design
Methodology ........................................................................................12
Exercises and Conceptual Problems ...........................................................17
Bibliography ...................................................................................................24
2. Electrical-Driven Actuating Elements: Modeling and Selection .......27
2.1 Introduction .........................................................................................27
2.2 Electrical-Driven Actuating Systems ...............................................27
2.2.1 Electromechanical Actuator .................................................29
2.2.2 DC Motor Dynamics Modeling ...........................................29
2.2.2.1 Self-Excited Series DC Motor ................................31
2.2.2.2 Self-Excited Shunt DC Motor ................................33
2.2.2.3 Separately Excited DC Motor ...............................34
2.2.2.4 Compound-Wound DC Motor .............................35
2.2.2.5 Permanent Magnet DC Motor ..............................37
2.2.2.6 Speed Control Methods of DC Motors ................38
2.2.3 AC Motor Technical Specifications and Dynamics
Modeling .................................................................................40
2.2.3.1 Induction Motor Dynamics Modeling ................43
2.2.3.2 Speed Control of AC Motors .................................49
2.2.4 Stepper Motors .......................................................................50
2.2.4.1 Stepper Motor Modeling .......................................51
2.3 Electrical Motor Sizing and Selection Procedure ...........................53
2.3.1 Electric Motor Selection ........................................................54
2.3.1.1 Electric Motor Operational Conditions
(Duty Cycle) ............................................................54
2.3.1.2 Motion Profile .........................................................56
vii
viii Contents
2.3.1.3 Load Torque Calculation .......................................58
2.3.1.4 Motor Shaft Torque Calculation ...........................59
2.3.1.5 Load Torque–Speed Profile Characteristics .......62
2.3.1.6 Matching Motor and Load Speed–Torque
Curves ......................................................................63
2.3.1.7 DC Motor Parameter Estimation .........................63
2.3.2 Process Dynamics Particularities ........................................69
2.3.2.1 Summary of Electric Motor Sizing
and Selection Procedure ........................................70
2.3.3 Electric Motor Interface and Accessories ...........................70
2.3.3.1 Power Source ...........................................................71
2.3.3.2 Power Converter .....................................................71
2.4 Modeling of Mechanical Transmission Elements ..........................74
2.5 Modeling of Electrofluidic Transmission Elements .......................78
2.5.1 Electric Pumps ........................................................................78
2.5.2 Electric Cylinders ...................................................................81
2.5.3 Electric Fans and Blowers .....................................................82
2.5.4 Fluid Flow–Controlled Electric Valves ...............................82
2.5.4.1 Valve Dynamic Equations .....................................84
2.6 Modeling of Electrothermal Transmission Elements ....................86
2.6.1 Electrical Heating Element Sizing and Selection ..............87
2.6.2 Control Requirements of Electrical Heating ......................88
2.7 Electrical Binary Actuators ................................................................88
2.7.1 Bistable Actuating Systems ..................................................88
2.7.2 Solid-State-Based Switching Power Electronics ................89
2.7.2.1 Power Diodes ..........................................................90
2.7.2.2 Power Transistors ...................................................90
2.7.2.3 Thyristors ................................................................94
2.7.2.4 Logic Integrated Circuit and Programmable
Logic Devices ..........................................................96
2.8 Solenoids ..............................................................................................97
Exercises and Problems .................................................................................98
Bibliography .................................................................................................107
3. Logic Controller Design ............................................................................111
3.1 Introduction .......................................................................................111
3.2 Logic System Design Preliminaries and Methods .......................112
3.2.1 Combinatorial and Sequential Logic Systems .................112
3.2.2 Sum of Product and Product of Sum Methods ................113
3.2.3 Karnaugh Maps ....................................................................116
3.2.4 Moore and Mealy State Diagrams .....................................117
3.2.5 Simplified State Diagram ....................................................121
3.2.6 Logic Controller Design Methods .....................................122
3.3 Process Description and Functional Analysis ..............................128
3.4 Formal Modeling of Discrete Systems ...........................................129
Contents ix
3.4.1 Process Modeling Using Truth Table and K-Maps .........130
3.4.2 Process Modeling Using Sequence Table Analysis
and Switching Theory .........................................................132
3.4.3 Process Modeling Using Simplified State Diagram ........136
3.4.4 Process Modeling Using Sequential Function Chart .....142
3.5 Logic Controller Circuit Design ......................................................142
3.6 Logic Controller Programming Languages ..................................147
3.6.1 Synchronizing Mechanism of Computer Program
Execution ...............................................................................148
3.6.2 Ladder Diagram ...................................................................148
3.6.2.1 Elements of the Ladder Diagram .......................149
3.6.3 Function Block ......................................................................152
3.6.3.1 Invocation and Incorporation of Functions
and Function Blocks .............................................154
3.6.4 Structured Text .....................................................................155
3.6.4.1 IF Statement (IF THEN or IF THEN ELSEIF) ...156
3.6.4.2 CASE Statement (in the Case of Multiple
Selections) ..............................................................157
3.6.5 Instruction List .....................................................................157
3.6.6 Sequential Function Chart ..................................................158
3.7 Wiring Diagram and Automation Project Documentation ........166
3.8 Sizing and Selection of Automation Systems................................173
3.8.1 Memory Structure and Capacity Estimation ...................174
3.8.2 Power Supply and I/O Unit ................................................177
3.9 Fail-Safe Design and Interlocks and Validation Issues ...............177
3.9.1 Logic Control Validation (Commissioning) .....................179
3.10 Illustrative Case Studies ...................................................................179
3.10.1 Fruit Packaging System Using Sequence Table ...............180
3.10.2 Fruit Picker Process Design Using Sequence Table ........183
3.10.3 Elevator-Based Motion Process ..........................................186
3.10.4 Automatic Ticket Gate .........................................................192
3.10.5 Mixing Juice Tank ................................................................195
3.10.6 Seaport Gantry Crane..........................................................196
Exercises and Problems ...............................................................................199
Bibliography .................................................................................................226
4. Process Monitoring, Fault Detection, and Diagnosis .........................227
4.1 Introduction .......................................................................................227
4.2 Requirements for Process Monitoring, Control, and Fault
Diagnosis ............................................................................................228
4.3 Monitoring System Architecture and Components .....................229
4.3.1 Process Database Structure Design...................................229
4.3.2 Process Data Acquisition and Monitoring Decision
Support System ....................................................................231
4.4 Operating Model and Fault Management of Processes ..............232