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Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering PDF

689 Pages·2019·13.655 MB·English
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M MMEECCHHAATTRROONNIICCSS 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 MMEECCHHAATTRROONNIICCSS mThoed ienrtne glirfaet wioonu olfd esleeecmtro inmicp oesnsgiibnleee. rFirnogm, m aeuctoh-afnoiccuasl ecnagmineeraesri ntog ,c caor netnroglin aen md caonmagpeumteern et nsgyisnteeemrisn, ga n– d fMroemch asttraoten-icosf- –th leie-sa ratt rtohbeo htse atort t ohfe t hhuem inbnluem wearsahbinleg g madagcheitnse, ,p Mroeccehsasterso naincds hteacsh an ohlaongdy iwn itthheomut awllh. ich E modern life would seem impossible. From auto-focus cameras to car engine management systems, and Tfrhoims bsotaotke -porfe-tsheen-tasr ta rcolbeoatrs a tno dth ceo hmupmrebhlee wnsaisvhei ningt rmoadcuhcitnioe,n M toe cthhaet raorneiac.s P hraasc ati chaaln adn idn athpepmlie adll, . E C it helps you to acquire the mix of skills you will need to comprehend and design mechatronic systems. ITt hailss ob ogooke sp mreuscehn dtse eap celre, aerx palnadin cinogm tphree vheernys pivheil oinsotrpohdyu ocft imone cthoa tthroen aicrse,a a. nPdr,a icnt sicoa dl oainndg ,a pprpolviiedde,s you C wit ihthe lap sfr yaomue t oof a ucnqdueirrset athned imngix t oo fd sekvielllosp y oau t rwuliyll inneteerdd itsoc cipolminaprrye haenndd i natnedgr daetesdig anp mpreocahcaht rtoo neincg sinyeseterimngs.. ELECTRONIC CONTROL SYSTEMS IN MECHANICAL H It also goes much deeper, explaining the very philosophy of mechatronics, and, in so doing, provides you with a frame of understanding to develop a truly interdisciplinary and integrated approach to engineering. ELECTRONIC CONTROL SYSTEMS IN MECHANICAL H AANNDD EELLEECCTTRRIICCAALL EENNGGIINNEEEERRIINNGG A This seventh edition has been updated with new sections and examples throughout: AANNDD EELLEECCTTRRIICCAALL EENNGGIINNEEEERRIINNGG • 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 N 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 Unit and Head of Research and Development and Monitoring aBti ltlh Beo Bltuosnin weasss faonrdm Teerclyh nCoolnosguyl tEadnutc taot itohne CFouurtnhceilr (EBdTuEcCa).t ion C S HUnei ht aasn da lHseoa bde oefn R ae UseNaErSchC Oa ncdo nDseuvletalonptm anedn ti sa nthde M onitoring aaut tthhoer B ouf sminaensys sauncdc eTsescfhunl oelnoggiyn eEedruincga ttieoxnt bCooouknsc.il (BTEC). S He has also been a UNESCO consultant and is the author of many successful engineering textbooks. SEVENTH SEEDVIETNIOTNH EDITION B O LB TO OL NT O N 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 CVR_BOLTON_07_50977.indd 1 21/08/2018 08:48 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 At Pearson, we have a simple mission: to help people make more of their lives through learning. We combine innovative learning technology with trusted content and educational expertise to provide engaging and effective learning experiences that serve people wherever and whenever they are learning. From classroom to boardroom, our curriculum materials, digital learning tools and testing programmes help to educate millions of people worldwide – more than any other private enterprise. Every day our work helps learning flourish, and wherever learning flourishes, so do people. To learn more, please visit us at www.pearson.com/uk F01 Mechatronics 50977 Contents.indd 2 30/08/2018 07:09 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: +44 (0)1279 623623 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 Licensing Agency Ltd, Barnard’s Inn, 86 Fetter Lane, London EC4A 1EN. 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 under which it was purchased, or as strictly permitted by applicable copyright law. Any unauthorised distribution or use of this text 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 endorsement of this book by such owners. 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 F01 Mechatronics 50977 Contents.indd 4 30/08/2018 07:09 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 F01 Mechatronics 50977 Contents.indd 5 30/08/2018 07:09 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 F01 Mechatronics 50977 Contents.indd 6 30/08/2018 07:09 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 F01 Mechatronics 50977 Contents.indd 7 30/08/2018 07:09 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 F01 Mechatronics 50977 Contents.indd 8 30/08/2018 07:09 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 F01 Mechatronics 50977 Contents.indd 9 30/08/2018 07:09

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