MechaReview (PDF)

MECHATRONICS SYSTEM \"AUTOMATION\" Transient Design - makes passenger impatient, make the uncomfortable. Steady-State response- **resemble the input** and is what remains after the transient have dieddown. STABILITY- total response- natural Response+ forced response, must approach zero leaving o...

MECHATRONICS SYSTEM \"AUTOMATION\" Transient Design - makes passenger impatient, make the uncomfortable. Steady-State response- **resemble the input** and is what remains after the transient have dieddown. STABILITY- total response- natural Response+ forced response, must approach zero leaving only the forced response AUTOMATION - **logical programming commands** and mechanized equipment to replace the decision making and manual command **ADVANTAGES**: Human operating performing tasks in dangerous environments, such as those with temperature extremes. Tasks that are beyond human capabilities are made easier. can easily incorporate quality checks and verification to reduce the number of out of tolerance parts. Can serve as the catalyst for improvement in the economics of enterprises or society. Do not call in silk. **DISADVANTAGE**: Current technology is unable to automate all desired tasks. Certain tasks would cost more to automate, perform manually. Automating a process is difficult to predict accurately beforehand. Initial cost are relatively high. AND OR. XOR. NAND NOR. XNOR 000\. 000. 000. 001. 001. 001 100\. 101. 101. 101. 100. 100 010\. 011 011 011. 010. 010 111\. 111. 110. 110. 110. 111 DIGITAL STATE- the most basic Element of automation logic **Using the PLC:** **1. Large Quantities of Contacts - PLCs efficiently manage multiple inputs and outputs, minimizing the complexity of physical wiring.** **2. Cost-Effectiveness - PLCs reduce overall costs by eliminating the need for mechanical relays and reducing labor and maintenance efforts.** **3. Security - PLCs offer secure access control for programming and operations, along with built-in safety features to prevent unauthorized changes.** **4. Documentation - Comprehensive documentation of settings, programs, and system configurations simplifies maintenance and troubleshooting.** **5. Pilot Running - PLCs can be tested through pilot runs before full implementation, ensuring system functionality without disrupting ongoing operations.** **6. Reliability - PLCs are highly reliable and designed to operate in harsh industrial environments, withstanding extreme temperatures and dust.** **7. Maintainability - Modular design and built-in diagnostics make PLCs easier to maintain and troubleshoot compared to traditional systems.** **8. Ease of Ordering Components - PLC components are easy to order and integrate, with manufacturers offering modular systems that are compatible and simple to configure.** **9. Speed of Operation (Scan Time) - PLCs operate at high speed, with quick scan times ensuring prompt response in real-time control applications.** **10. Visualization - PLCs integrate with visualization tools (HMIs) for clear monitoring and interaction with the system via graphical interfaces.** **11. Programming Method - PLCs support various programming methods, including ladder logic and function block diagrams, allowing flexibility in automation design.** **APPLICATION OF PLC:** ** Process Control - PLCs are widely used in process control to automate industrial processes. They monitor and control variables such as temperature, pressure, and flow rates, ensuring optimal operation and safety.** ** Conveyor System - Conveyor System: PLCs manage conveyor systems in manufacturing and logistics, controlling the speed, direction, and operation of the conveyors to ensure efficient material handling and movement.,** ** Food Processing Machinery - the food industry, PLCs are employed to automate machinery used for mixing, cooking, and packaging food products. They ensure precise control and consistency in food production processes.** ** Filling plants - PLCs are crucial in filling plants for automating the filling of containers with liquids or solids. They control the filling process, monitor levels, and ensure accuracy and efficiency.** ** Woodworking - In woodworking applications, PLCs control machines such as saws, routers, and lathes. They automate processes like cutting, shaping, and finishing wood products, enhancing precision and reducing manual labor** **TYPE OF PLC** ** Process Control - Analog Input** ** Machine Control - Discret Input** **Digital Input: digital signals have non-continuous electrical signals** ** Inductive Sensor - Detects the presence of metallic objects without contact, based on changes in electromagnetic fields.** ** Capacitive Sensor - Detects the presence of both metallic and non-metallic objects, including liquids and granular materials, by measuring changes in capacitance.** ** Sonar Sensor - Measures distance by sending ultrasonic waves and detecting the echo; used for non-contact detection of objects.** ** Limit Switch - A mechanical device that detects the physical limit or position of an object and activates a switch when the object comes into contact.** ** Electromechanical Switch - A traditional switch that operates through mechanical movement to open or close electrical contacts** **Analog Input: refers to the input signals that are continuous in nature and vary over time. These signals represent real-world phenomena like temperature, pressure, or load** ** Level Sensor - Measures the level of liquids or solids and provides a continuous signal indicating the level (e.g., in a tank).** ** Thermocouple Sensor - Measures temperature by generating a voltage that varies with the temperature difference.** ** Resistance Temperature Detector - Measures temperature by correlating the resistance of the RTD element with temperature.** ** Load Cell - Measures force or weight by converting mechanical force into an electrical signal, which varies based on the load applied.** **Digital Output:** **- To operate solenoid valves, relays, indicating lamps or as a command to any other devices** **-ON/OFF** **-binary outputs (0 or 1, also called as high and low level) from the PLC. It is a processed control output from the PLC to the field. It is used to ON or OFF any piece of field equipment.** **Digital Output Module the Load:.** **Lamps - for indicator** **Contactors - large amount similar from relay but large amount (High C)** **Tacometer-** **Manometer -** **Type of fuels:** ** Jet Fuel** ** Gasoline** ** Diesel** ** Banker Fuel** ** Asphalt** **Isc-Starting current 250%** **Ifl- Full current 10A** **Solenoid** **-For irrigate** **-converts electrical energy into mechanical work through electromagnetic forces.** **ANALOG OUTPUT TO LOAD - Valve** **RACK** **- Components that holds everything together** **-Depending on the needs of the control system (different sizes)** **POWER SUPPLY** **- Supplies from DC** **-plug into the rack as supplies** **CPU-Brain of PLC** **SCAN TIME- In the range 1/1000th of a seconds** **VOLATILE MEMORY - back to zero (temporary) S7/200 memory system** **Data memory -Values of Input and output** **Example of PLC - SIEMENS PG 740** **I/O -provides the physical connection between** **1970s &1980s - First Programmable Logic Controllers by MODICON challenges GM ( GENERAL MOTORS)** **PLC DO ?** ** SEQUENCE CONTROL** **-Conventional Relay Logic Replacer** **-Timers/Counters** **-PCB CARD CONTROLLER REPLACER** **-Auto/Semi - Auto/Manual control machine processes** ** SOPHISTICATED CONTROL** **-Arithmetic Operation** **-Information Handling** **-Analog Control** **-PID(Proportional-Integral-Derivatives** **- Servo Motor Control** **- Stepper Motor Control** ** SUPERVISORY** **- Processing Monitoring and Alarm** **-Fault Detection and Diagnosis** **-Factory Automation Networking** **-Interfacing w/computer** **-Printer/ASCII Interfacing** **-Local Area Network, Wide Area Network etc.** **Devices which can connect to PLC** **- PLC (two way)** **- Barcode Reader (One Way)** **- Net work (two way)** **- Computer (two way)** **- PG702 (two way)** **Benefits of PLC** **- flexibility** **- implementing changes and correcting errors** **INDUSTRIAL AUTOMATION** **Industrial - having a lot of industry and factories** **Automation -Use machine, compute can operate w/o human control** **Two main classification of Industrial control** **-Process** **-Motor** **Control System -set of devices that manage and commands directs** **INDUSTRIAL CONTROL SYSTEM** **Motion control -Servo** **Process Control - Variable regulator** **Batch process - Sequential processing** **REQUIREMENT OF GOOD CONTROL SYSTEM** **1. Accuracy - measurements of tolerance limit** **2. Sensitivity - insentive such parameters but sensitive** **3. Noise - Undesired signal** **4. Stability - bounded input signal** **5. Bandwidth l- operating frequency range** **6. Speed - The transient period for such period is very small** **-Good control system posseses high speed** **-time taken by the control system (Achieve stable output)** **7. Oscillation - Small numbers of oscillations** **- Constant oscillation of output** **-Tend to indicate the system to be stable** **Open loop Control System - Control action is totally independent of output of the system** **Advantages:** **-Simple in Construction and Design** **-Economical** **-Easy to maintain** **-Generally Stable** **Disadvantage:** **-They are innacurate** **-Thet are unreliable** **-Any change in output cannot be correted automatically.** **Closed Loop Control System - output has an effect** **Advantages:** **1. More Accurate in the presence of NON-LINEARITY** **2. High accurate as any error** **3. Bandwidth range is large** **4. Facilities automation** **5. sensitivity of system maybe made small to make system more stable** **6. Less affected by noise** **Disadvantage:** **-They are costlier** **-They are complicated to design** **-Required more maintenance** **-Feedbacj leads to oscillatory response** **-Overall gain is reduced to presence of feedback** **-Stability is the major problem and more care is needed to design a stable closed system** ** FEEDBACK LOOP OF CONTROL SYSTEM** **Control System (Example)** **-Temperature control in a furnace** **-Elevator Position Control** **-Antenna Positioning System** **-Robotic Manipulator Control** **-Control of Internal Combustion Engine** **For control systems, the natural repense must approach zerd leaving on the forced response. If the natural response grows without bounds, we have instability.** **\"SWITCH\"** **DIP SWITCH** **- a set of small manual electronic switches that are designed to be packaged with other circuits.** **-are typically presented as a row of tiny toggle (on/off) switches, rather like a series of miniature standard light switches,** **Type:** ** Rocker Type: Features a lever that rocks back and forth, providing a clear visual indication of its position. Ideal for applications needing easy operation.** ** DPST Type (Double Pole Single Throw): Controls two circuits simultaneously with one action. Perfect for isolating multiple circuits.** ** Tristate Type: Offers three positions: on, off, or high-impedance state. Useful in digital circuits to disconnect devices while maintaining status.** ** Piano Type: Compact switches arranged like piano keys, ideal for space-limited devices. Each switch controls a different function.** ** Slide Type: Utilizes a sliding mechanism for making or breaking connections. Common in consumer electronics for tactile feedback and position clarity.** ** Rotary Type: Uses a rotating knob for multiple settings, great for volume controls or mode selection, allowing easy adjustments.** **Tactile Switch** **- Tactile (touch, tangible) design to be package** **-switch that completes an electrical circuit typically when pressure is applied to the device by the user, which then gives the user a perceptible "click" or haptic bump in response, indicating current flow. Current flow is turned off when the switch is released.** **Type:** ** Standard Type** ** Ultra Subminiature Type** ** Horizontal Type** ** Long stroke Type** ** Hinge Lever type** **Sealed Tactile Switch** **Type:** ** Standard type** ** Radial taping type** ** Low profile type** ** Medium stroke Type** **Slide Switch** **-to control current flow in a circuit** **-use a mechanical slee to a switch current** **Example:** ** Vertical slide** ** Horizontal** ** Mini Vertical Slide** ** Mini Horizontal slide Switch** **TYPE:** ** OFF TYPE** ** ON TYPE** ** ON/OFF/ON TYPE** **Push Button Switch** **- mechanical switches** **-Activate the switch** **-Activation method is typically in the form of of a plunge (push down to open)** **Example :** ** Mini-type** ** push to make and push to break type** ** Tactile Type** ** latching type** **Limit Switch** **- Detetection switch which consists Of a basic switch in a metal or resin case.** **- the strong outer case protects inside of the switch for external forrces, moisture, oill, dust and dirt that it can be used in locations that demand mechanical strength and enviromental resistance.** **- Contact gap** **Rocker switch - operation that can be pressed on either end** **Types:** **Miniature Types -16A, 10A, 15x21mm** **Sealed Types -16A, 17 x 24mm** **Two-button- 16A Types** **Illuminated types -16A, 25x32mm** **Resettable types -20A, 27x37mm** **Operating Body - part of a machine or equipment** **Moving contact - moving spring part of mechanism for touching from seperating from the fixed contact** **Type: Crossbar contact** **Main Material: Gold Allay, Silver Alloy** **Processing Method: Welding and Riveting.** **Main Application: Crossbar used for ensuring high contact.** **Type: Needle** **Main Material: Silver** **Processing Method:** **Main Application: Welding & Riveting** **-ensuring improvement in contact reliability for switchin.** **Type: Rivet** **Pressure Switch** **- activates or deactivate (device) in a electrical.** **Purpose: it monitor the pressure** **Type:** **Direct type** **Bellows type** **Bordon type** **Piston type(pressure switch combines a piston and resistance)** **Latching Circuit** **-is an electromechanical switch commonly selected when the operator must control (either switch off or amplify) a large amount of current flow.** **-How is it work? can activated by an electrical signal, such as from a push button an a relay.** **electroneumatic Cirquit \"dominant ON\" and \"dominant OFF\"**