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MECHATRONICS SECONDEDITION MECHATRONICS with Experiments SABRI CETINKUNT UniversityofIllinoisatChicago,USA Thiseditionfirstpublished2015 ©2015JohnWiley&SonsLtd Registeredoffice JohnWiley&SonsLtd,TheAtrium,SouthernGate,Chichester,WestSussex,PO198SQ,UnitedKingdom Fordetailsofourglobaleditorialoffices,forcustomerservicesandforinformationabouthowtoapplyfor permissiontoreusethecopyrightmaterialinthisbookpleaseseeourwebsiteatwww.wiley.com. Therightoftheauthortobeidentifiedastheauthorofthisworkhasbeenassertedinaccordancewiththe Copyright,DesignsandPatentsAct1988. Allrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmitted,in anyformorbyanymeans,electronic,mechanical,photocopying,recordingorotherwise,exceptaspermittedby theUKCopyright,DesignsandPatentsAct1988,withoutthepriorpermissionofthepublisher. Wileyalsopublishesitsbooksinavarietyofelectronicformats.Somecontentthatappearsinprintmaynotbe availableinelectronicbooks. 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MATLAB®isatrademarkofTheMathWorks,Inc.andisusedwithpermission.TheMathWorksdoesnot warranttheaccuracyofthetextorexercisesinthisbook.Thisbook’suseordiscussionofMATLAB®software orrelatedproductsdoesnotconstituteendorsementorsponsorshipbyTheMathWorksofaparticular pedagogicalapproachorparticularuseoftheMATLAB®software. LibraryofCongressCataloging-in-PublicationData Cetinkunt,Sabri. [Mechatronics] Mechatronicswithexperiments/SabriCetinkunt.–Secondedition. pagescm RevisededitionofMechatronics/SabriCetinkunt.2007 Includesbibliographicalreferencesandindex. ISBN978-1-118-80246-5(cloth) 1.Mechatronics. I.Title. TJ163.12.C432015 621.381–dc23 2014032267 AcataloguerecordforthisbookisavailablefromtheBritishLibrary. ISBN:9781118802465 Setin10/12ptTimesbyAptaraInc.,NewDelhi,India 1 2015 CONTENTS PREFACE xi 2.3 OpenLoopControlVersus ClosedLoopControl 63 ABOUTTHECOMPANIONWEBSITE xii 2.4 PerformanceSpecificationsfor ControlSystems 67 CHAPTER1 INTRODUCTION 1 2.5 TimeDomainandS-domain 1.1 CaseStudy:Modelingand CorrelationofSignals 69 ControlofCombustionEngines 16 2.6 TransientResponse 1.1.1 DieselEngine Specifications:Selectionof Components 17 PoleLocations 70 1.1.2 EngineControlSystem 2.6.1 StepResponseofa Components 23 Second-OrderSystem 70 1.1.3 EngineModelingwith 2.6.2 StandardFilters 74 LugCurve 25 2.7 Steady-StateResponse 1.1.4 EngineControl Specifications 74 Algorithms:Engine 2.8 StabilityofDynamicSystems 76 SpeedRegulation 2.8.1 BoundedInput–Bounded usingFuelMapanda OutputStability 77 ProportionalControl 2.9 ExperimentalDeterminationof Algorithm 29 FrequencyResponse 78 1.2 Example:Electro-hydraulic 2.9.1 Graphical FlightControlSystemsfor Representationof CommercialAirplanes 31 FrequencyResponse 79 1.3 EmbeddedControlSoftware 2.9.2 StabilityAnalysisin DevelopmentforMechatronic theFrequency Systems 38 Domain:Nyquist 1.4 Problems 43 StabilityCriteria 87 2.10 TheRootLocusMethod 89 CHAPTER2 CLOSEDLOOP 2.11 CorrelationBetweenTime CONTROL 45 DomainandFrequencyDomain Information 93 2.1 ComponentsofaDigital 2.12 BasicFeedbackControlTypes 97 ControlSystem 46 2.12.1 ProportionalControl 100 2.2 TheSamplingOperationand 2.12.2 DerivativeControl 101 SignalReconstruction 48 2.12.3 IntegralControl 102 2.2.1 Sampling:A/D 2.12.4 PIControl 103 Operation 48 2.12.5 PDControl 106 2.2.2 SamplingCircuit 48 2.12.6 PIDControl 107 2.2.3 Mathematical 2.12.7 Practical Idealizationofthe ImplementationIssues SamplingCircuit 50 ofPIDControl 111 2.2.4 SignalReconstruction: 2.12.8 TimeDelayinControl D/AOperation 55 Systems 117 2.2.5 Real-timeControl 2.13 TranslationofAnalogControl UpdateMethodsand toDigitalControl 125 TimeDelay 58 2.13.1 FiniteDifference 2.2.6 Filteringand Approximations 126 BandwidthIssues 60 2.14 Problems 128 v vi CONTENTS CHAPTER3 MECHANISMSFOR 4.2 BasicComputerModel 214 MOTIONTRANSMISSION 133 4.3 MicrocontrollerHardwareand Software:PIC18F452 218 3.1 Introduction 133 4.3.1 Microcontroller 3.2 RotarytoRotaryMotion Hardware 220 TransmissionMechanisms 136 4.3.2 Microprocessor 3.2.1 Gears 136 Software 224 3.2.2 BeltandPulley 138 4.3.3 I/OPeripheralsofPIC 3.3 RotarytoTranslationalMotion 18F452 226 TransmissionMechanisms 139 4.4 Interrupts 235 3.3.1 Lead-Screwand 4.4.1 GeneralFeaturesof Ball-Screw Interrupts 235 Mechanisms 139 4.4.2 InterruptsonPIC 3.3.2 RackandPinion 18F452 236 Mechanism 142 4.5 Problems 243 3.3.3 BeltandPulley 142 3.4 CyclicMotionTransmission CHAPTER5 ELECTRONIC Mechanisms 143 COMPONENTSFOR 3.4.1 Linkages 143 MECHATRONICSYSTEMS 245 3.4.2 Cams 145 3.5 ShaftMisalignmentsand 5.1 Introduction 245 FlexibleCouplings 153 5.2 BasicsofLinearCircuits 245 3.6 ActuatorSizing 154 5.3 EquivalentElectricalCircuit 3.6.1 InertiaMatchBetween Methods 249 MotorandLoad 160 5.3.1 Thevenin’sEquivalent 3.7 HomogeneousTransformation Circuit 249 Matrices 162 5.3.2 Norton’sEquivalent 3.8 ACaseStudy:Automotive Circuit 250 Transmissionasa“Gear 5.4 Impedance 252 Reducer” 172 5.4.1 ConceptofImpedance 252 3.8.1 TheNeedfora 5.4.2 Amplifier:Gain,Input Gearbox Impedance,and “Transmission”in OutputImpedance 257 Automotive 5.4.3 InputandOutput Applications 172 LoadingErrors 258 3.8.2 Automotive 5.5 SemiconductorElectronic Transmission:Manual Devices 260 ShiftType 174 5.5.1 Semiconductor 3.8.3 PlanetaryGears 178 Materials 260 3.8.4 TorqueConverter 186 5.5.2 Diodes 263 3.8.5 ClutchesandBrakes: 5.5.3 Transistors 271 MultiDiscType 192 5.6 OperationalAmplifiers 282 3.8.6 Example:An 5.6.1 BasicOp-Amp 282 Automatic 5.6.2 CommonOp-Amp TransmissionControl Circuits 290 Algorithm 194 5.7 DigitalElectronicDevices 308 3.8.7 Example:Powertrain 5.7.1 LogicDevices 309 ofArticulatedTrucks 196 5.7.2 Decoders 309 3.9 Problems 201 5.7.3 Multiplexer 309 5.7.4 Flip-Flops 310 5.8 DigitalandAnalogI/Oand CHAPTER4 TheirComputerInterface 314 MICROCONTROLLERS 207 5.9 D/AandA/DConvertersand TheirComputerInterface 318 4.1 EmbeddedComputersversus 5.10 Problems 324 Non-EmbeddedComputers 207 CONTENTS vii CHAPTER6 SENSORS 329 6.9.2 TemperatureSensors BasedonResistance 382 6.1 IntroductiontoMeasurement 6.9.3 Thermocouples 383 Devices 329 6.10 FlowRateSensors 385 6.2 MeasurementDeviceLoading 6.10.1 MechanicalFlowRate Errors 333 Sensors 385 6.3 WheatstoneBridgeCircuit 335 6.10.2 DifferentialPressure 6.3.1 NullMethod 336 FlowRateSensors 387 6.3.2 DeflectionMethod 337 6.10.3 FlowRateSensor 6.4 PositionSensors 339 BasedonFaraday’s 6.4.1 Potentiometer 339 InductionPrinciple 389 6.4.2 LVDT,Resolver,and 6.10.4 ThermalFlowRate Syncro 340 Sensors:HotWire 6.4.3 Encoders 346 Anemometer 390 6.4.4 HallEffectSensors 351 6.10.5 MassFlowRate 6.4.5 CapacitiveGap Sensors:CoriolisFlow Sensors 353 Meters 391 6.4.6 Magnetostriction 6.11 HumiditySensors 393 PositionSensors 354 6.12 VisionSystems 394 6.4.7 SonicDistanceSensors 356 6.13 GPS:GlobalPositioningSystem 397 6.4.8 PhotoelecticDistance 6.13.1 OperatingPrinciplesof andPresenceSensors 357 GPS 399 6.4.9 PresenceSensors: 6.13.2 SourcesofErrorin ON/OFFSensors 360 GPS 402 6.5 VelocitySensors 362 6.13.3 DifferentialGPS 402 6.5.1 Tachometers 362 6.14 Problems 403 6.5.2 DigitalDerivationof VelocityfromPosition CHAPTER7 ELECTROHYDRAULIC Signal 364 MOTIONCONTROLSYSTEMS 407 6.6 AccelerationSensors 365 6.6.1 Inertial 7.1 Introduction 407 Accelerometers 366 7.2 FundamentalPhysical 6.6.2 Piezoelectric Principles 425 Accelerometers 370 7.2.1 AnalogyBetween 6.6.3 Strain-gaugeBased Hydraulicand Accelerometers 371 ElectricalComponents 429 6.7 Strain,Force,andTorque 7.2.2 EnergyLossand Sensors 372 PressureDropin 6.7.1 StrainGauges 372 HydraulicCircuits 431 6.7.2 ForceandTorque 7.3 HydraulicPumps 437 Sensors 373 7.3.1 TypesofPositive 6.8 PressureSensors 376 DisplacementPumps 438 6.8.1 DisplacementBased 7.3.2 PumpPerformance 443 PressureSensors 378 7.3.3 PumpControl 448 6.8.2 Strain-GaugeBased 7.4 HydraulicActuators:Hydraulic PressureSensor 379 CylinderandRotaryMotor 457 6.8.3 PiezoelectricBased 7.5 HydraulicValves 461 PressureSensor 380 7.5.1 PressureControl 6.8.4 CapacitanceBased Valves 463 PressureSensor 380 7.5.2 Example:Multi 6.9 TemperatureSensors 381 FunctionHydraulic 6.9.1 TemperatureSensors CircuitwithPoppet BasedonDimensional Valves 469 Change 381 7.5.3 FlowControlValves 471 viii CONTENTS 7.5.4 Example:AMulti 8.1.2 ElectricFieldsand FunctionHydraulic MagneticFields 610 Circuitusing 8.1.3 PermanentMagnetic Post-Pressure Materials 622 Compensated 8.2 EnergyLossesinElectric ProportionalValves 482 Motors 629 7.5.5 Directional, 8.2.1 ResistanceLosses 631 Proportional,and 8.2.2 CoreLosses 632 ServoValves 484 8.2.3 FrictionandWindage 7.5.6 MountingofValvesin Losses 633 aHydraulicCircuit 496 8.3 Solenoids 633 7.5.7 Performance 8.3.1 OperatingPrinciplesof Characteristicsof Solenoids 633 ProportionalandServo 8.3.2 DCSolenoid: Valves 497 Electromechanical 7.6 SizingofHydraulicMotion DynamicModel 636 SystemComponents 507 8.4 DCServoMotorsandDrives 640 7.7 HydraulicMotionAxisNatural 8.4.1 OperatingPrinciplesof FrequencyandBandwidthLimit 518 DCMotors 642 7.8 LinearDynamicModelofa 8.4.2 DrivesforDC One-AxisHydraulicMotion Brush-typeand System 520 BrushlessMotors 650 7.8.1 PositionControlled 8.5 ACInductionMotorsandDrives 659 Electrohydraulic 8.5.1 ACInductionMotor MotionAxes 523 OperatingPrinciples 660 7.8.2 LoadPressure 8.5.2 DrivesforAC Controlled InductionMotors 666 Electrohydraulic 8.6 StepMotors 670 MotionAxes 526 8.6.1 BasicStepperMotor 7.9 NonlinearDynamicModelof OperatingPrinciples 672 One-AxisHydraulicMotion 8.6.2 StepMotorDrives 677 System 527 8.7 LinearMotors 681 7.10 Example:OpenCenter 8.8 DCMotor:Electromechanical HydraulicSystem–Forceand DynamicModel 683 SpeedModulationCurvesin 8.8.1 VoltageAmplifier SteadyState 571 DrivenDCMotor 687 7.11 Example:Hydrostatic 8.8.2 CurrentAmplifier Transmissions 576 DrivenDCMotor 687 7.12 CurrentTrendsin 8.8.3 Steady-State Electrohydraulics 586 Torque-Speed 7.13 CaseStudies 589 CharacteristicsofDC 7.13.1 CaseStudy:Multi MotorUnderConstant FunctionHydraulic TerminalVoltage 688 CircuitofaCaterpillar 8.8.4 Steady-State WheelLoader 589 Torque-Speed 7.14 Problems 593 CharacteristicofaDC MotorUnderConstant CHAPTER8 ELECTRIC CommandedCurrent ACTUATORS:MOTORANDDRIVE Condition 689 TECHNOLOGY 603 8.9 Problems 691 8.1 Introduction 603 CHAPTER9 PROGRAMMABLE 8.1.1 Steady-State LOGICCONTROLLERS 695 Torque-SpeedRange, Regeneration,and 9.1 Introduction 695 PowerDumping 606