Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering

689 Pages·2019·13.655 MB·English

by  William Charles Bolton

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The integration of electronic engineering, mechanical engineering, control and computer engineering –
Mechatronics – lies at the heart of the innumerable gadgets, processes and technology without which M
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it helps you to acquire the mix of skills you will need to comprehend and design mechatronic systems.
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It also goes much deeper, explaining the very philosophy of mechatronics, and, in so doing, provides you
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• Updated coverage of mechatronic system components, including extended coverage of A
This seventh edition has been updated with new sections and examples throughout: T
encoders, position sensitive detectors and force sensitive resistors
WILLIAM BOLTON
• Updated coverage of mechatronic system components, including extended coverage of
• New material on Atmega microcontrollers including applications and programming examples T
encoders, position sensitive detectors and force sensitive resistors
• Topical discussion and examples of fuzzy logic and neural control systems R WILLIAM BOLTON
• New material on Atmega microcontrollers including applications and programming examples
Applications and case studies have been revised across the book, with fascinating examples R
• Topical discussion and examples of fuzzy logic and neural control systems
including automated guided vehicles, to help you to gain a modern and practical understanding. O
Applications and case studies have been revised across the book, with fascinating examples
including automated guided vehicles, to help you to gain a modern and practical understanding. O
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Mechatronics is essential reading for students requiring an introduction
to this exciting area at undergraduate and higher diploma level. N
Mechatronics is essential reading for students requiring an introduction I
to this exciting area at undergraduate and higher diploma level.
B ill Bolton was formerly Consultant to the Further Education CI
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He has also been a UNESCO consultant and is the
author of many successful engineering textbooks.
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Cover images © Paper Boat Creative/DigitalVision/Getty Images www.pearson-books.com
& bubaone/DigitalVision Vectors/Getty Images
Cover images © Paper Boat Creative/DigitalVision/Getty Images www.pearson-books.com SEVENTH EDITION
& bubaone/DigitalVision Vectors/Getty Images
SEVENTH EDITION
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CVR_BOLTON_07_50977.indd 1 21/08/2018 08:48
M E C H AT RO N I C S
F01 Mechatronics 50977 Contents.indd 1 30/08/2018 07:09
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MECHATRONICS
ELECTRONIC CONTROL SYSTEMS IN
MECHANICAL AND ELECTRICAL
ENGINEERING
Seventh Edition
William Bolton
Harlow, England • London • New York • Boston • San Francisco • Toronto • Sydney
Dubai • Singapore • Hong Kong • Tokyo • Seoul • Taipei • New Delhi
Cape Town • São Paulo • Mexico City • Madrid • Amsterdam • Munich • Paris • Milan
F01 Mechatronics 50977 Contents.indd 3 30/08/2018 07:09
Pearson Education Limited
KAO Two
KAO Park
Harlow CM17 9NA
United Kingdom
Tel: [phone]
Web: www.pearson.com/uk
First published 1995 (print)
Second edition published 1999 (print)
Third edition published 2003 (print)
Fourth edition published 2008 (print)
Fifth edition published 2011 (print and electronic)
Sixth edition published 2015 (print and electronic)
Seventh edition published 2019 (print and electronic)
© Pearson Education Limited 2015, 2019 (print and electronic)
The right of William Bolton to be identified as author of this work has been asserted by him in accordance with the Copyright,
Designs and Patents Act 1988.
The print publication is protected by copyright. Prior to any prohibited reproduction, storage in a retrieval system, distribution or
transmission in any form or by any means, electronic, mechanical, recording or otherwise, permission should be obtained from the
publisher or, where applicable, a licence permitting restricted copying in the United Kingdom should be obtained from the Copyright
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The ePublication is protected by copyright and must not be copied, reproduced, transferred, distributed, leased, licensed or publicly
performed or used in any way except as specifically permitted in writing by the publishers, as allowed under the terms and conditions
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may be a direct infringement of the author’s and the publisher’s rights and those responsible may be liable in law accordingly.
All trademarks used herein are the property of their respective owners. The use of any trademark in this text does not vest in the author
or publisher any trademark ownership rights in such trademarks, nor does the use of such trademarks imply any affiliation with or
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Pearson Education is not responsible for the content of third-party internet sites.
ISBN: 978-1-292-25097-7 (print)
978-1-292-25100-4 (PDF)
978-1-292-25099-1 (ePub)
British Library Cataloguing-in-Publication Data
A catalogue record for the print edition is available from the British Library
Library of Congress Cataloging-in-Publication Data
Names: Bolton, W. (William), 1933- author.
Title: Mechatronics : electronic control systems in mechanical and electrical
engineering / William Bolton.
Description: Seventh edition. | Harlow, England ; New York : Pearson
Education Limited, 2019. | Includes bibliographical references and index.
Identifiers: LCCN 2018029322| ISBN 9781292250977 (print) | ISBN 9781292251004
(pdf) | ISBN 9781292250991 (epub)
Subjects: LCSH: Mechatronics.
Classification: LCC TJ163.12 .B65 2019 | DDC 621—dc23
LC record available at https://urldefense.proofpoint.com/v2/url?u=https-3A__lccn.loc.gov_2018029322&d=DwIFAg&c=0YLnzTkW
OdJlub_y7qAx8Q&r=eK0q0-QqUPIJD1OLTc7YiWdHxmNowNBMcvK9N3XeA-U&m=KkECpIRxvUd6hHO4IgYQ39O8Wnj16yu
FhTNaAb0czTk&s=d_M15Lwv7uWaxVKsm14kfkQ5Quu9-ZHwFQvuouRdve8&e=
10 9 8 7 6 5 4 3 2 1
23 22 21 20 19
Print edition typeset in 10/11 pt Ehrhardt MT Pro by Pearson CSC
Printed and bound in Malaysia
NOTE THAT ANY PAGE CROSS REFERENCES REFER TO THE PRINT EDITION
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Contents
Preface xi 3. Signal conditioning 78
Chapter objectives 78
I. Introduction 1 3.1 Signal conditioning 78
3.2 The operational amplifier 79
1. Introducing mechatronics 3 3.3 Protection 90
3.4 Filtering 91
3.5 Wheatstone bridge 92
Chapter objectives 3 3.6 Pulse modulation 97
1.1 What is mechatronics? 3 3.7 Problems with signals 98
1.2 The design process 5 3.8 Power transfer 100
1.3 Systems 6 Summary 101
1.4 Measurement systems 8 Problems 101
1.5 Control systems 9
1.6 Programmable logic controller 21
1.7 Examples of mechatronic systems 22 4. Digital signals 103
Summary 26
Problems 27
Chapter objectives 103
4.1 Digital signals 103
4.2 Analogue and digital signals 103
II. Sensors and signal conditioning 29
4.3 Digital-to-analogue and analogue-to-digital
converters 107
2. Sensors and transducers 31 4.4 Multiplexers 113
4.5 Data acquisition 114
4.6 Digital signal processing 116
Chapter objectives 31 4.7 Digital signal communications 118
2.1 Sensors and transducers 31 Summary 119
2.2 Performance terminology 32 Problems 120
2.3 Displacement, position and proximity 37
2.4 Velocity and motion 54
2.5 Force 57
5. Digital logic 121
2.6 Fluid pressure 57
2.7 Liquid flow 61
2.8 Liquid level 62 Chapter objectives 121
2.9 Temperature 63 5.1 Digital logic 121
2.10 Light sensors 69 5.2 Logic gates 122
2.11 Selection of sensors 70 5.3 Applications of logic gates 130
2.12 Inputting data by switches 71 5.4 Sequential logic 135
Summary 74 Summary 143
Problems 75 Problems 143
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vi CONTENTS
6. Data presentation systems 146 9. Electrical actuation systems 222
Chapter objectives 146 Chapter objectives 222
6.1 Displays 146 9.1 Electrical systems 222
6.2 Data presentation elements 147 9.2 Mechanical switches 222
6.3 Magnetic recording 152 9.3 Solid-state switches 224
6.4 Optical recording 157 9.4 Solenoids 231
6.5 Displays 157 9.5 Direct current motors 232
6.6 Data acquisition systems 162 9.6 Alternating current motors 241
6.7 Measurement systems 166 9.7 Stepper motors 243
6.8 Testing and calibration 169 9.8 Direct current servomotors 250
Summary 171 9.9 Motor selection 251
Problems 172 Summary 255
Problems 255
III. Actuation 175 IV. Microprocessor systems 257
7. Pneumatic and hydraulic actuation 10. Microprocessors and microcontrollers 259
systems 177
Chapter objectives 259
Chapter objectives 177 10.1 Control 259
7.1 Actuation systems 177 10.2 Microprocessor systems 259
7.2 Pneumatic and hydraulic systems 177 10.3 Microcontrollers 270
7.3 Directional control valves 181 10.4 Applications 296
7.4 Pressure control valves 186 10.5 Programming 297
7.5 Cylinders 188 Summary 300
7.6 Servo and proportional control valves 192 Problems 300
7.7 Process control valves 193
Summary 198
11. Assembly language 301
Problems 198
Chapter objectives 301
11.1 Languages 301
8. Mechanical actuation systems 201 11.2 Assembly language programs 302
11.3 Instruction sets 304
11.4 Subroutines 317
Chapter objectives 201
11.5 Look-up tables 321
8.1 Mechanical systems 201
11.6 Embedded systems 324
8.2 Types of motion 202
Summary 327
8.3 Kinematic chains 204
Problems 328
8.4 Cams 208
8.5 Gears 210
8.6 Ratchet and pawl 214
12. C language 329
8.7 Belt and chain drives 214
8.8 Bearings 216
8.9 Electromechanical linear actuators 218 Chapter objectives 329
Summary 219 12.1 Why C? 329
Problems 220 12.2 Program structure 329
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CONTENTS vii
12.3 Branches and loops 336 15.5 Open Systems Interconnection communication
12.4 Arrays 340 model 415
12.5 Pointers 342 15.6 Serial communication interfaces 418
12.6 Program development 343 15.7 Parallel communication interfaces 427
12.7 Examples of programs 345 15.8 Wireless communications 430
12.8 Arduino programs 348 Summary 431
Summary 352 Problems 432
Problems 352
13. Input/output systems 354 16. Fault finding 433
Chapter objectives 354 Chapter objectives 433
13.1 Interfacing 354 16.1 Fault-detection techniques 433
13.2 Input/output addressing 355 16.2 Watchdog timer 434
13.3 Interface requirements 357 16.3 Parity and error coding checks 435
13.4 Peripheral interface adapters 364 16.4 Common hardware faults 437
13.5 Serial communications interface 369 16.5 Microprocessor systems 438
13.6 Examples of interfacing 372 16.6 Evaluation and simulation 441
Summary 380 16.7 PLC systems 442
Problems 380 Summary 445
Problems 445
14. Programmable logic controllers 382
V. System models 447
Chapter objectives 382
14.1 Programmable logic controller 382
17. Basic system models 449
14.2 Basic PLC structure 382
14.3 Input/output processing 386
14.4 Ladder programming 387 Chapter objectives 449
14.5 Instruction lists 391 17.1 Mathematical models 449
14.6 Latching and internal relays 394 17.2 Mechanical system building blocks 450
14.7 Sequencing 396 17.3 Electrical system building blocks 458
14.8 Timers and counters 397 17.4 Fluid system building blocks 462
14.9 Shift registers 400 17.5 Thermal system building blocks 469
14.10 Master and jump controls 401 Summary 472
14.11 Data handling 402 Problems 473
14.12 Analogue input/output 404
Summary 406
Problems 407
18. System models 475
15. Communication systems 409
Chapter objectives 475
18.1 Engineering systems 475
Chapter objectives 409 18.2 Rotational–translational systems 475
15.1 Digital communications 409 18.3 Electromechanical systems 476
15.2 Centralised, hierarchical and distributed 18.4 Linearity 479
control 409 18.5 Hydraulic–mechanical systems 481
15.3 Networks 412 Summary 484
15.4 Protocols 414 Problems 484
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viii CONTENTS
22.8 Controller tuning 564
19. Dynamic responses of systems 485
22.9 Velocity control 566
22.10 Adaptive control 567
Chapter objectives 485 Summary 569
19.1 Modelling dynamic systems 485 Problems 569
19.2 Terminology 486
19.3 First-order systems 488
19.4 Second-order systems 494 23. Artificial intelligence 571
19.5 Performance measures for second-order systems 501
19.6 System identification 504
Summary 505 Chapter objectives 571
Problems 506 23.1 What is meant by artificial intelligence? 571
23.2 Perception and cognition 572
23.3 Fuzzy logic 575
20. System transfer functions 509 Summary 585
Problems 586
Chapter objectives 509
20.1 The transfer function 509
VI. Conclusion 587
20.2 First-order systems 512
20.3 Second-order systems 514
24. Mechatronic systems 589
20.4 Systems in series 516
20.5 Systems with feedback loops 517
20.6 Effect of pole location on transient response 519 Chapter objectives 589
Summary 522 24.1 Mechatronic designs 589
Problems 522 24.2 Robotics 600
24.3 Case studies 606
Summary 625
21. Frequency response 524 Problems 625
Research assignments 625
Design assignments 625
Chapter objectives 524
21.1 Sinusoidal input 524
21.2 Phasors 525
Appendices 627
21.3 Frequency response 527
21.4 Bode plots 530
A The Laplace transform 629
21.5 Performance specifications 539
21.6 Stability 541
Summary 543 A.1 The Laplace transform 629
Problems 544 A.2 Unit steps and impulses 630
A.3 Standard Laplace transforms 632
A.4 The inverse transform 636
Problems 638
22. Closed-loop controllers 546
Chapter objectives 546
B Number systems 639
22.1 Control processes 546
22.2 Two-step or on/off mode 548
22.3 Proportional mode of control 550 B.1 Number systems 639
22.4 Integral mode of control 552 B.2 Binary mathematics 640
22.5 Derivative mode of control 555 B.3 Floating numbers 643
22.6 PID controller 557 B.4 Gray code 643
22.7 Digital control systems 559 Problems 644
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CONTENTS ix
C.4 Karnaugh maps 649
C Boolean algebra 645
Problems 652
C.1 Laws of Boolean algebra 645
C.2 De Morgan’s laws 646 Answers 654
C.3 Boolean function generation from truth tables 647 Index 669
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