MECHATRONICS. SABRI CETINKUNT University of Illinois at Chicago WILEY JOHN WILEY & SONS, INC.

Transcription

1 MECHATRONICS SABRI CETINKUNT University of Illinois at Chicago WILEY JOHN WILEY & SONS, INC.

2 CONTENTS PREFACE vii CHAPTER 1 INTRODUCTION TO MECHATR0N1CS Introduction Case Study: Modeling and Control of Combustion Engines Diesel Engine Components 14 l.2.2 Engine Control System Components Engine Modeling with Lug Curve Engine Control Algorithms: Engine Speed Regulation Using Fuel Map and a Proportional Control Algorithm Problems 26 CHAPTER 2 CLOSED-LOOP CONTROL Components of a Digital Control System The Sampling Operation and Signal Reconstruction Sampling: A/D Operation Sampling Circuit Mathematical Idealization of the Sampling Circuit Signal Reconstruction: D/A Operation Real-Time Control Update Methods and Titne-Delay Filtering and Bandwidth Issues Open-Loop Control versus Closcd-Loop Control Performance Specifications for Control Systems Time Domain and s-domain Correlation of Signals Selection of Pole Locations Step Response of a Seeond-Order System Standard Filters Steady-State Response Stability of Dynamic Systems Bounded Input-Bounded Output Stability The Root Locus Method Basic Feedback Control Typcs Proportional Control Derivative Control Integral Control PI Control PD Control PID Control Translation of Analog Control to Digital Control Finite Difference Approximations Problems 78 CHAPTER 3 MECHANISMS FOR MOTION TRANSMISSION Introduction Rotary-to-Rotary Motion Transmission Mechanisms Gears Belt and Pulley Rotary-to-Translational Motion Transmission Mechanisms Lead Screw and Ball Screw Mechanisms Rack-and-Pinion Mechanism Belt and Pulley Cyclic Motion Transmission Mechanisms Linkages Cams Shaft Misalignments and Flexible Couplings Actuator Si/.ing Inertia Match Between Motor and Load Homogeneous Transformation Matrices Problems 119 CHAPTER 4 MICROCONTROLLERS Embeddcd Computers versus Nonembeddcd Computers Design Steps of an Embedded Microcontroller-Based Mechatronic System 125

3 IV CONTENTS Microcontroller Development Tools Microcontroller Development Tools t'orpic 18F Basic Computer Model Microcontroller Hardware and Software: PIC 18F Microcontroller Hardware Microproccssor Software I/OPeripheratsofPIC I8F Interrupts General Features of Interrupts Interrupts on PIC 18F Problems 152 CHAPTER 5 ELECTRONIC COMPONENTS EOR MECHA TRONIC S YSTEMS Introduction Basics of Linear Circuits Equivalcnt HIectrical Circuit Methods Thevenin's Equivalcnt Circuit Norton's Equivalent Circuit Impedance Concept of Impedance Amplilier: Gain. Inpul Impedance, and Output Impedance Input and Output Loading Errors Semiconductor Electronic Devices Semiconductor Materials Diodes Transistors Operational Amplifiers Basic Op-Amp Common Op-Amp Circuits Digital Electronic Devices Logic Devices Decoders Multiplexcr Flip-Flops Digital and Analog I/O and Thcir Computer Interface D/A and A/D Converters and Their Computer Interface Problems 214 CHAPTER 6 SENSORS Introduction to Measurement Devices Measurement Device Loading Errors Wheatstone Bridge Circuit Null Method Deflection Method Position Sensors Potentiometer LVDT, Resolver. and Syncro Encoders Hall Effect Sensors Capaeitive Gap Sensors Magnetostriction Position Sensors Sonic Distance Sensors Photoelcctric Distance and Presence Sensors Presence Sensors: ON/OFF Sensors Velocity Sensors Tachometers Digital Derivation of Velocity from Position Signal Acccleration Sensors Inertial Accelerometers Piezoelectric Accelerometers Strain-Gauge-Based Accelerometers Strain, Force, and Torque Sensors Strain Gauges Force and Torque Sensors Pressure Sensors Displacement-Based Pressure Sensors Strain-Gauge-Based Pressure Sensor Piezoclectric-Based Pressure Sensor Capaeitance-Based Pressure Sensor Temperaturc Sensors Temperature Sensors Based on Dimensional Change Temperature Sensors Based on Resistance Thcrmocouples Flow Rate Sensors K). I Mechanical Flow Rate Sensors Differential Pressure Flow Rate Sensors Thermal Flow Rate Sensors: Hot Wire Anemometer Mass Flow Rate Sensors: Coriolis Flow Meters l Humidity Sensors Vision Systems Problems 277 CHAPTER 7 ELECTROHYDRA ULIC MOTION CONTROL SYSTEMS Introduction Fundamental Physical Principles 294

4 CONTENTS V Analogy Between Hydraulic and Electrical Components Energy Loss and Pressure Drop in Hydraulic Circuits Hydraulic Pumps Types of Positive Displacement Pumps Pump Performance Pump Control Hydraulic Actuators: Hydraulic Cylinder and Rotary Motor Hydraulic Valves Pressure Control Valves Example: Multifunction Hydraulic Circuit with Poppet Valves Flow Control Valves Example: A Multifunction Hydraulic Circuit Using Post-Pressure Compensated Proportional Valves Directional Flow Control Valves: Proportional and Servo Valves Mounting of Valves in a Hydraulic Circuit Performance Characteristics of Proportional and Servo Valves Sizing of Hydraulic Motion System Components EH Motion Axis Natural Frequency and Bandwidth Limit Linear Dynamic Model of a One-Axis Hydraulic Motion System Position Controlled Electrohydraulic Motion Axes Load Pressure Controlled Electrohydraulic Motion Axes Nonlinear Dynamic Model of a Hydraulic Motion System Current Trends in Electrohydraulics Case Studies Case Study: Multifunction Hydraulic Circuit of a Caterpillar Wheel Loader II Problems 388 CHAPTER 8 ELECTRIC A CTUA TORS: MOTOR AND DRIVE TECHNOLOGY Introduction Stcady-State Torque-Speed Range. Regeneration, and Power Dumping Electric Fields and Magnetic Fields Permanent Masinetic Materials Solenoids Operating Principles of Solenoids DC Solenoid: Electromechanical Dynamic Model DC Servo Motors and Drives Operating Principles of DC Motors Drives for DC Brush-Type and Brushless Motors AC Induction Motors and Drives AC Induction Motor Operating Principles Drives for AC Induction Motors Step Motors Basic Stepper Motor Operating Principles Step Motor Drives Switched Reluctance Motors and Drives Switched Reluctance Motors SR Motor Control System Components: Drive Linear Motors DC Motor: Electromechanical Dynamic Model Voltage Amputier Drivcn DC Motor Current Amplifier Driven DC Motor Steady-State Torque-Speed Characteristics of a DC Motor under Constant Terminal Voltage Steady-State Torque-Speed Characteristics of a DC Motor and Current Amplifier Energy Losses in Electric Motors Resistance Losses Core Losses Friction and Windage Losses Problems 491 CHAPTER 9 PROCRAMMABLE LOGIC CONTROLLERS Introduction Hardware Components of PLCs PLC. CPU, and I/O Capabilities Opto-Isolated Discrete Input and Output Modules Relays, Contactors, Starters Counters and Timers Programming of PLCs Hardwired Seal-In Circuit PLC Control System Applications 510

5 VI CONTENTS 9.5 PLC Application Example: Conveyor and Furnace Control Problems 514 CHAPTER10 PROGRAMMABLE MOTION CONTROL SYSTEMS lntroduction Design Methodology l'or PMC Systems Motion Controller Hardware and Software Basic Single-Axis Motions Coordinatcd Motion Control Methods Point-to-Point Synchronized Motion Electronic Gearing Coordinated Motion CAM Profile and Contouring Coordinated Motion Sensor-Based Real-Time Coordinated Motion Coordinated Motion Applications Web Handling with Registration Mark Web Tension Control Using Electronic Gearing Smart Conveyors Problems 544 APPENDIX A TABLES 547 APPENDIX B MODELING AND SIMUIA T/ON OF D YNAMIC SYSTEMS 549 B.l Modeling of Dynamic Systems 549 B.2 Complex Variables 550 B.3 Laplace Transforms 552 B.3. l Definition of Laplace Transform 552 B.3.2 Properties of the Laplace Transform 554 B.3.3 Laplace Transforms of Some Common Functions 558 B.3.4 Inverse Laplace Transform: Using Partial Fraction Expansions 562 B.4 Fourier Series, Fourier Transforms, and Frequency Response 566 B.4.1 Basics of Frequency Response: Meaning of Frequency Response 571 B.4.2 Relationship Betwcen the Frequency Response and Transfer Function 572 B.4.3 s-domain Interpretation of Frequency Response 573 B.4.4 Experimental Determination of Frequency Response 574 B.4.5 Graphical Representation of Frequency Response 574 B.5 Transfer Function and Impulse Response Relation 574 B.6 Convolution 579 B.7 Review of Differential Equations 581 B.7.1 Definitions 581 B.7.2 System of First-Order O.D.E.s 581 B.7.3 Existence and Uniqueness of the Solution ofo.d.e.s 582 B.8 Linearization 583 B.8.1 Linearization of Nonlinear Functions 583 B.8.2 Linearization of Nonlinear First-Order Differential Equations 585 B.8.3 Linearization of Multidimensional Nonlinear Differential Equations 586 B.9 Numciical Solution ofo.d.e.s and Simulation of Dynamic Systems 588 B.9.1 Numerical Methods for Solving O.D.E.s 589 B.9.2 Numerical Solution ofo.d.e.s 589 B.9.3 Time Domain Simulation of Dynamic Systems 591 B. 10 Details of the Solution for Example on Page 162: RL and RC Circuits 600 B.ll Problems 604 B1BLIOGRAPHY 607 INDEX 611