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Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Visit the Taylor & Francis Web site at http://www.com and the CRC Press Web site at http://www.com To Professor Jim A. Poo for his friendship and continuous support. “We live in a society exquisitely dependent on science and technology, in which hardly anyone knows anything about science and technology.” Carl Sagan Contents Preface .3 Modeling and Design .4 Mechatronic Design Concept .2 Mechatronic Design Quotient .5 Evolution of Mechatronics .7 Study of Mechatronics.8 Organization of the Book.
Basic Elements and Components.1 Fluid Capacitor or Accumulator (A-Type Element) .4 Derivation of Constitutive Equations .30 vii viii Contents 2.3 Three-Dimensional Conduction .2 Lead Screw and Nut .6 Passive Electrical Elements and Materials .1 Conductance and Resistance .3 Effect of Temperature on Resistance .4 Effect of Strain on Resistance .6 Color Code for Fixed Resistors .2 Dielectric Material and Capacitor Element .3 Color Code for Fixed Capacitors .3 Magnetic Material and Inductor Element .1 Magnetism and Permeability .5 Hall-Effect Sensors .6 Magnetic Bubble Memories .7 Active Electronic Components .9 Schottky Barrier Diodes .1 Bipolar Junction Transistors .2 Field-Effect Transistors .4 The Junction Field Effect Transistor .8 Light Emitters and Displays .1 Light-Emitting Diodes.3 Liquid Crystal Displays .4 Photo-Field Effect Transistor .6 Charge-Coupled Device.7 Applications of Optically Coupled Devices. Modeling of Mechatronic Systems .2 Dynamic Systems and Models .3 Types of Analytical Models .4 Principle of Superposition.3 Lumped Model of a Distributed System .3 Lumped Elements and Analogies .1 Across Variables and through Variables .4 Analytical Model Development .1 Steps of Model Development .2 Input–Output Models .3 State-Space Models .1 Linear State Equations .1 Linearization about an Operating Point .2 Function of Two Variables .3 Reduction of System Nonlinearities.4 Linearization Using Experimental Operating Curves .1 Torque–Speed Curves of Motors.2 Linear Models for Motor Control.1 Variables and Sign Convention .2 Linear Graph Elements .1 Single-Port Elements .2 Two-Port Elements .3 Linear Graph Equations .4 State Models from Linear Graphs .4 Linear Graph Representation .5 Linear Graphs of Thermal Systems .7 Transfer Functions and Frequency-Domain Models .2 Frequency-Domain Models .1 Frequency Transfer Function (Frequency Response Function) .2 Bode Diagram (Bode Plot) and Nyquist Diagram .3 Transfer Functions of Electromechanical Systems .1 Mechanical Transfer Functions .2 Transfer Functions of Basic Elements.8 Equivalent Circuits and Linear Graph Reduction .1 Thevenin’s Theorem for Electrical Circuits.2 Mechanical Circuit Analysis Using Linear Graphs .1 Simulation Block Diagrams .2 Principle of Superposition .3 Causality and Physical Realizability .2 First-Order Systems .3 Second-Order Systems .1 Free Response of Undamped Oscillator .2 Free Response of Damped Oscillator .3 Forced Response of Damped Oscillator.4 Response Using Laplace Transform .1 Step Response Using Laplace Transforms .2 Incorporation of Initial Conditions.3 Step Response of a First-Order System .5 Determination of Initial Conditions for Step Response .1 Use of Simulink® in Computer Simulation .3 Building an Application. Component Interconnection and Signal Conditioning .1 Cascade Connection of Devices .3 Impedance Matching in Mechanical Systems .1 Use of Feedback in Op-Amps .2 Voltage and Current Amplifiers .4 Amplifier Performance Ratings .1 Common-Mode Rejection Ratio .2 AC-Coupled Amplifiers .5 Ground Loop Noise .1 Passive Filters and Active Filters .1 Number of Poles .2 Low-Pass Filters.1 Low-Pass Butterworth Filter .3 High-Pass Filters .4 Band-Pass Filters .1 Resonance-Type Band-Pass Filters .2 Band-Reject Filters .1 Software and Hardware Implementations .5 Modulators and Demodulators .2 Side Frequencies and Side Bands .2 Application of Amplitude Modulation .1 Fault Detection and Diagnosis .6 Analog-to-Digital Conversion .1 Digital-to-Analog Conversion .1 Weighted Resistor DAC .3 DAC Error Sources .2 Analog-to-Digital Conversion .1 Successive Approximation ADC .2 Dual Slope ADC .4 ADC Performance Characteristics .3 Sample-and-Hold Circuitry .2 Constant-Current Bridge .3 Hardware Linearization of Bridge Outputs.5 Half-Bridge Circuits.2 Wien-Bridge Oscillator. Instrument Ratings and Error Analysis .1 Parameters for Performance Specification .2 Perfect Measurement Device.4 The Jump Phenomenon.1 Transmission Level of a Band-Pass Filter .2 Effective Noise Bandwidth .3 Half-Power (or 3 dB) Bandwidth .4 Fourier Analysis Bandwidth .5 Useful Frequency Range .5 Signal Sampling and Aliasing Distortion .2 Anti-Aliasing Filter .3 Another Illustration of Aliasing .6 Bandwidth Design of a Control System .1 Comment about Control Cycle Time.7 Instrument Error Analysis.2 Accuracy and Precision.8 Statistical Process Control.1 Control Limits or Action Lines .2 Steps of SPC.
Sensors and Transducers.2 Motion Sensors and Transducers .3 Variable-Inductance Transducers .1 Mutual-Induction Transducers .2 Linear-Variable Differential Transformer.1 Phase Shift and Null Voltage .4 Self-Induction Transducers.5 Eddy Current Transducers .6 Permanent-Magnet Tachometers .8 Permanent-Magnet AC Tachometer .9 AC Induction Tachometer .4 Variable-Capacitance Transducers .1 Capacitive Rotation Sensor .2 Capacitive Displacement Sensor.3 Capacitance Bridge Circuit .2 Types of Accelerometers .1 Equations for Strain Gage Measurements.2 The Bridge Constant .2 Semiconductor Strain Gages .1 Strain Gage Torque Sensors.1 Tactile Sensor Requirements .2 Construction and Operation of Tactile Sensors .3 Optical Tactile Sensors .4 Piezoresistive Tactile Sensors .2 Coriolis Force Devices .10 Optical Sensors and Lasers .1 Fiber-Optic Position Sensor .3 Fiber-Optic Gyroscope .4 Laser Doppler Interferometer .1 Magnetostrictive Displacement Sensors .12 Thermo-Fluid Sensors .2 Resistance Temperature Detector .4 Bimetal Strip Thermometer .1 Advantages of Digital Transducers .3 Incremental Optical Encoder .1 Direction of Rotation .6 Step-Up Gearing .10 Step-Up Gearing .11 Data Acquisition Hardware .4 Absolute Optical Encoders .2 Code Conversion Logic .3 Advantages and Drawbacks .14 Miscellaneous Digital Transducers .3 Hall-Effect Sensors .5 Moiré Fringe Displacement Sensors .7 Other Types of Sensors .1 Image Processing and Computer Vision .2 Image-Based Sensory System.2 Image Frame Acquisition .1 Stepper Motor Classification .2 Hybrid Stepper Motor .4 Driver and Controller .6 Stepper Motor Selection .1 Torque Characteristics and Terminology .2 Stepper Motor Selection Process .7 Stepper Motor Applications .1 Rotor and Stator .3 Brushless DC Motors.4 DC Motor Equations .1 Steady-State Characteristics .5 Experimental Model for DC Motor .1 Electrical Damping Constant .2 Linearized Experimental Model .6 Control of DC Motors .2 Motor Time Constants .7 Feedback Control of DC Motors .1 Velocity Feedback Control .2 Position Plus Velocity Feedback Control .3 Position Feedback with PID Control .9 DC Motor Selection.1 Motor Data and Specifications .3 Motor Sizing Procedure .5 Drive Amplifier Selection.1 Rotating Magnetic Field .2 Induction Motor Characteristics .3 Torque–Speed Relationship.4 Induction Motor Control .1 Excitation Frequency Control .3 Field Feedback Control (Flux Vector Drive) .5 A Transfer-Function Model for an Induction Motor .6 Single-Phase AC Motors .1 Control of a Synchronous Motor.1 Components of a Hydraulic Control System .2 Hydraulic Pumps and Motors.2 Steady-State Valve Characteristics .4 Hydraulic Primary Actuators .5 The Load Equation.6 Hydraulic Control Systems.7 Constant-Flow Systems .8 Pump-Controlled Hydraulic Actuators .10 Pneumatic Control Systems. Digital Hardware and Microcontrollers .2 Number Systems and Codes .1 Signed Magnitude Representation .2 Two’s Complement Representation .3 Binary Multiplication and Division .4 Binary Gray Codes .5 Binary Coded Decimal .3 Logic and Boolean Algebra .1 Sum and Product Forms.4 Combinational Logic Circuits .2 IC Logic Families .3 Design of Logic Circuits .3 Active-Low Signals .1 Karnaugh Map Method .5 Sequential Logic Devices .1 RS Flip-Flop .3 JK Flip-Flop .5 T Flip-Flop and Counters.6 Practical Considerations of IC Chips.1 IC Chip Production .1 Arithmetic Logic Unit.4 Accumulator and Data Register .1 RAM, ROM, PROM, EPROM, and EEPROM .2 Bits, Bytes, and Words .4 Physical Form of Memory .6 Memory Card Design .4 Input/Output Hardware.1 Microcontroller Pin-Out .4 Direct Memory Access Method.6 Clock, Counter, and Timer .5 Microcontroller Programming and Program Execution .1 Instruction Set, Operation Codes, and Mnemonics .2 Programming and Languages .4 Real-Time Processing .6 Development of Microcontroller Applications .2 Control System Structure .1 Feedback and Feedforward Control .2 Programmable Logic Controllers .3 Control System Performance .1 Performance Specification in Time Domain .1 Simple Oscillator Model .1 Feedback Control with PID Action .1 System Type and Error Constants .2 Performance Specification Using s-Plane .1 Routh–Hurwitz Criterion .3 Zero Coefficient Problem .2 Root Locus Method .1 Root Locus Rules .2 Steps of Sketching Root Locus .3 Stability in the Frequency Domain .3 Phase Margin and Gain Margin .4 Bode and Nyquist Plots .1 Linear Quadratic Regulator Control .3 Nonlinear Feedback Control .5 Sliding Mode Control .6 Linear Quadratic Gaussian Control .7 Fuzzy Logic Control .2 Fuzzy Sets and Membership Functions .3 Fuzzy Logic Operations .4 Compositional Rule of Inference .1 Extensions to Fuzzy Decision Making .5 Basics of Fuzzy Control.6 Fuzzy Control Surface .1 Computer Control Systems.2 Components of a Digital Control System .3 Advantages of Digital Control. Case Studies in Mechatronics .1 Engineering Design as an Optimization Problem .4 Quality Function Deployment .6 Design of a Mechatronic System .3 Robotics Case Study .4 Robot Design and Development .3 Actuator Selection/Sizing .5 Amplifiers and Power Supplies .4 Iron Butcher Case Study .3 Control System Architecture .1 Motor Control Console .1 Physical Parameters of the Cutter Table.2 Hydraulic Piston Parameters .3 Flow Control Servovalves .1 Project 1: Automated Glue Dispensing System .2 Project 2: Material Testing Machine .3 Project 3: Active Orthosis.4 Project 4: Railway Car Braking System.5 Project 5: Machine Tool Control System .6 Project 6: Welding Robot.7 Project 7: Wood Strander.8 Project 8: Automated Mining Shovel .9 Project 9: Can-Filling Machine.10 Project 10: Fish-Marking Machine .11 Project 11: Machine for Grading Herring Roe .12 Project 12: Hydraulic Control System. 755 Appendix A: Solid Mechanics .1 General Problem of Elasticity .2 Plane Strain Problem .3 Plane Stress Problem .3 Plane Stress Problem in Polar Coordinates .2 Rotating Thick Cylinders .2 Stress–Strain (Constitutive) Relations .3 Particular Cases of Cylinders .1 Case 1: Axially Restrained Ends .2 Case 2: Thick Pressure Vessel .3 Case 3: Thin Pressure Vessel .4 Case 4: Rotating Cylinder with Free Ends .5 Mohr’s Circle of Plane Stress .7 Beams in Bending and Shear .2 Maxwell’s Theorem of Reciprocity .3 Castigliano’s First Theorem .4 Elastic Energy of Bending .8 Open-Coiled Helical Springs .