Mechatronics Electronic control systems in mechanical and electrical engineering Sixth Edition William Bolton 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) © Pearson Education Limited 2015 (print and electronic) ISBN: 978-1-292-07668-3 (print) 978-1-292-08159-5 (PDF) 978-1-292-08160-1 (eText) 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 Bolton, W. (William), 1933– Mechatronics : a multidisciplinary approach / William Bolton. pages cm Includes bibliographical references and index.B65 2015 621–dc23 2014041487 Contents Preface xi 3. Signal conditioning 69 chapter objectives 69 I.2 the operational amplifier 70 1.4 Filtering 83 chapter objectives 3 3.1 What is mechatronics? 3 3.2 the design process 5 3.7 Problems with signals 89 1.4 Measurement systems 8 summary 92 1.5 control systems 9 Problems 93 1.6 Programmable logic controller 21 1.7 examples of mechatronic systems 22 summary 25 4.
Digital signals 95 Problems 26 chapter objectives 95 4.1 Digital signals 95 II. Sensors and signal conditioning 27 4.2 analogue and digital signals 95 4.3 Digital-to-analogue and analogue-to-digital 2. Sensors and transducers 29 converters 99 4.5 Data acquisition 106 chapter objectives 29 4.6 Digital signal processing 109 2.1 sensors and transducers 29 summary 110 2.2 Performance terminology 30 Problems 110 2.3 Displacement, position and proximity 35 2.4 Velocity and motion 46 2.8 Liquid level 55 chapter objectives 112 2.11 selection of sensors 62 5.3 applications of logic gates 120 2.12 inputting data by switches 63 5.4 sequential logic 126 summary 65 summary 133 Problems 66 Problems 133 6. Data presentation systems 136 9.
Electrical actuation systems 207 Chapter objectives 136 Chapter objectives 207 6.2 Data presentation elements 137 9.3 Solid-state switches 209 6.5 Direct current motors 217 6.6 Data acquisition systems 151 9.6 Alternating current motors 225 6.8 Testing and calibration 158 9.8 Motor selection 234 Summary 160 Summary 237 Problems 160 Problems 237 III. Pneumatic and hydraulic actuation 10. Microprocessors and microcontrollers 241 systems 165 Chapter objectives 241 Chapter objectives 165 10.2 Pneumatic and hydraulic systems 165 10.3 Directional control valves 169 10.4 Pressure control valves 173 10.6 Servo and proportional control Problems 277 valves 178 7.7 Process control valves 180 7. Assembly language 278 Summary 186 Problems 186 Chapter objective 278 11.
Mechanical actuation systems 188 11.3 Assembly language programs 285 11.5 Look-up tables 293 Chapter objectives 188 11.1 Mechanical systems 188 Summary 300 8.2 Types of motion 189 Problems 300 8.6 Ratchet and pawl 200 12.7 Belt and chain drives 200 8.8 Bearings 202 Chapter objectives 302 Summary 204 12.3 Branches and loops 309 15.5 Open Systems Interconnection 12.6 Program development 316 communication model 382 12.7 Examples of programs 317 15.6 Serial communication interfaces 385 12.7 Parallel communication interfaces 391 Summary 323 15.8 Wireless protocols 394 Problems 324 Summary 395 Problems 395 13. Input/output systems 326 16. Fault finding 397 Chapter objectives 326 13.1 Interfacing 326 Chapter objectives 397 13.2 Input/output addressing 326 16.1 Fault-detection techniques 397 13.4 Peripheral interface adapters 336 16.3 Parity and error coding checks 399 13.5 Serial communications interface 341 16.4 Common hardware faults 400 13.6 Examples of interfacing 344 16.5 Microprocessor systems 402 Summary 347 16.6 Emulation and simulation 405 Problems 348 16.7 PLC systems 407 Summary 409 Problems 410 14. Programmable logic controllers 349 V.
System models 411 Chapter objectives 349 14.1 Programmable logic controller 349 17. Basic system models 413 14.2 Basic PLC structure 349 14.3 Input/output processing 353 14.4 Ladder programming 354 Chapter objectives 413 14.6 Latching and internal relays 361 17.2 Mechanical system building blocks 414 14.3 Electrical system building blocks 422 14.8 Timers and counters 364 17.4 Fluid system building blocks 426 14.5 Thermal system building blocks 433 14.10 Master and jump controls 368 Summary 436 14.11 Data handling 369 Problems 437 14.12 Analogue input/output 371 Summary 373 Problems 374 18. System models 439 Chapter objectives 439 15.2 Rotational–translational systems 439 18.3 Electro-mechanical systems 440 Chapter objectives 376 18.5 Hydraulic–mechanical systems 445 15.2 Centralised, hierarchical and distributed Summary 448 control 376 Problems 448 22. Dynamic responses of systems 449 22.6 Integral control 514 Chapter objectives 449 22.1 Modelling dynamic systems 449 22.9 Control system performance 520 19.3 First-order systems 452 22.4 Second-order systems 458 22.5 Performance measures for second-order 22.12 Adaptive control 523 systems 464 Summary 526 19.6 System identification 467 Problems 527 Summary 467 Problems 469 23.
System transfer functions 471 Chapter objectives 528 23.1 What is meant by artificial intelligence? 528 Chapter objectives 471 23.2 Perception and cognition 528 20.1 The transfer function 471 23.2 First-order systems 474 23.3 Second-order systems 476 Summary 534 20.4 Systems in series 478 Problems 534 20.5 Systems with feedback loops 479 20.6 Effect of pole location on transient response 480 Summary 484 VI. Frequency response 486 Chapter objectives 537 24.1 Mechatronic designs 537 Chapter objectives 486 24.3 Frequency response 489 Problems 567 21.4 Bode plots 492 Research assignments 568 21.5 Performance specifications 501 Design assignments 568 21.6 Stability 502 Summary 503 Problems 504 Appendices 569 A The Laplace transform 571 22. Closed-loop controllers 505 A.1 The Laplace transform 571 Chapter objectives 505 A.2 Unit steps and impulses 572 22.1 Continuous and discrete control processes 505 A.3 Standard Laplace transforms 574 22.4 The inverse transform 578 22.3 Two-step mode 509 Problems 580 B Number systems 581 E C library functions 601 B.3 Floating numbers 585 F MATLAB and SIMULINK 604 B.4 Gray code 585 Problems 586 F.2 SIMULINK 608 C Boolean algebra 587 G Electrical circuit analysis 610 C.1 Laws of Boolean algebra 587 C.2 De Morgan’s laws 588 C.3 Boolean function generation from truth tables 589 G.1 Direct current circuits 610 C.2 Alternating current circuits 615 Problems 594 Further information 620 D Instruction sets 596 Answers 624 Index 639 Preface the term mechatronics was ‘invented’ by a Japanese engineer in 1969, as a combination of ‘mecha’ from mechanisms and ‘tronics’ from electronics. the word now has a wider meaning, being used to describe a philosophy in engineering technology in which there is a co-ordinated, and concurrently developed, integration of mechanical engineering with electronics and intelligent computer control in the design and manufacture of products and processes.
as a result, many products which used to have mechanical functions have had many replaced with ones involving microprocessors. this has resulted in much greater flexibility, easier redesign and reprogramming, and the ability to carry out automated data collection and reporting. a consequence of this approach is the need for engineers and technicians to adopt an interdisciplinary and integrated approach to engineering. thus engineers and technicians need skills and knowledge that are not confined to a single subject area.
they need to be capable of operating and communicating across a range of engineering disciplines and linking with those having more specialised skills. this book is an attempt to provide a basic background to mechatronics and provide links through to more specialised skills. the first edition was designed to cover the Business and technology education council (Btec) Mechatronics units for higher national certificate/Diploma courses for technicians and designed to fit alongside more specialist units such as those for design, manufacture and maintenance determined by the application area of the course. the book was widely used for such courses and has also found use in undergraduate courses in both Britain and in the United states.
Following feedback from lecturers in both Britain and the United states, the second edition was considerably extended and with its extra depth it was not only still relevant for its original readership but also suitable for undergraduate courses. the third edition involved refinements of some explanations, more discussion of microcontrollers and programming, increased use of models for mechatronics systems, and the grouping together of key facts in the appendices. the fourth edition was a complete reconsideration of all aspects of the text, both layout and content, with some regrouping of topics, movement of more material into appendices to avoid disrupting the flow of the text, new material – in particular an introduction to artificial intelligence, more case studies and a refinement of some topics to improve clarity. also, objectives and key point summaries were included with each chapter.
the fifth edition kept the same structure but, after consultation with many users of the book, many aspects had extra detail and refinement added. The sixth edition has involved a restructuring of the constituent parts of the book as some users felt that the chapter sequencing did not match the general teaching sequence. Thus the new edition has involved moving the system models part so that it comes after microprocessor systems. Other changes include the inclusion of material on Arduino and the addition of more topics in the Mechatronics Systems chapter.
The overall aim of the book is to give a comprehensive coverage of mechatronics which can be used with courses for both technicians and undergraduates in engineering and, hence, to help the reader: • acquire a mix of skills in mechanical engineering, electronics and computing which is necessary if he/she is to be able to comprehend and design mechatronics systems; • become capable of operating and communicating across the range of engineering disciplines necessary in mechatronics; • be capable of designing mechatronic systems. Each chapter of the book includes objectives, and a summary, is copiously illustrated and contains problems, answers to which are supplied at the end of the book. Chapter 24 comprises research and design assignments together with clues as to their possible answers. The structure of the book is: • Chapter 1 is a general introduction to mechatronics; • Chapters 2–6 form a coherent block on sensors and signal conditioning; • Chapters 7–9 cover actuators; • Chapters 10–16 discuss microprocessor/microcontroller systems; • Chapters 17– 23 are concerned with system models; • Chapter 24 provides an overall conclusion in considering the design of mechatronic systems.
An Instructor’s Guide, test material and Powerpoint slides are available for lecturers to download at: www.uk/bolton A large debt is owed to the publications of the manufacturers of the equipment referred to in the text. I would also like to thank those reviewers who painstakingly read through the fifth edition and made suggestions for improvements. Bolton Chapter one Introducing mechatronics objectives The objectives of this chapter are that, after studying it, the reader should be able to: • Explain what is meant by mechatronics and appreciate its relevance in engineering design. • Explain what is meant by a system and define the elements of measurement systems.
• Describe the various forms and elements of open-loop and closed-loop control systems. • Recognise the need for models of systems in order to predict their behaviour.1 What is mechatronics? The term mechatronics was ‘invented’ by a Japanese engineer in 1969, as a combination of ‘mecha’ from mechanisms and ‘tronics’ from electronics. The word now has a wider meaning, being used to describe a philosophy in engineering technology in which there is a co-ordinated, and concurrently developed, integration of mechanical engineering with electronics and intelligent computer control in the design and manufacture of products and processes. As a result, mechatronic products have many mechanical functions replaced with electronic ones.
This results in much greater flexibility, easy redesign and reprogramming, and the ability to carry out automated data collection and reporting. A mechatronic system is not just a marriage of electrical and mechanical systems and is more than just a control system; it is a complete integration of all of them in which there is a concurrent approach to the design. In the design of cars, robots, machine tools, washing machines, cameras and very many other machines, such an integrated and interdisciplinary approach to engineering design is increasingly being adopted. The integration across the traditional boundaries of mechanical engineering, electrical engineering, electronics and control engineering has to occur at the earliest stages of the design process if cheaper, more reliable, more flexible systems are to be de- veloped.