Mechatrohhvcfghnnbvffgnncddnics All Chapter.pdf

Mechatronics
Department of Mechanical Engineering
2 September 2023
Rift Valley University Bishoftu
Campus

Books
References:
1. Robert H. Bishop. Editor-in-chief. “The Mechatronics Handbook”, CRC Press, with
ISA–The Instrumentation, Systems, Automation Society (50 Chapters), 2002. ISBN: 0-
8493-0066-5 44
2. G. Webster. Editor-in-chief. “Measurement, Instrumentation, and Sensors
Handbook” CRC Press. 1999. 0-8493-2145-X.
3. Dan S. Necsulescu, Mechatronics, Prentice Hall, 2002, (311 p.). ISBN: 0-201-44491-7
4. VICTOR GIURGIUTIU and SERGEY EDWARD LYSHEVSKI.
“MICROMECHATRONICS - Modeling, Analysis, and Design with MATLAB”. CRC
PRESS, Boca Raton London New York Washington, D.C. (ISBN: 0-8493-1593-X).
2004.
2 September 2023

Chapter one
Introduction to Mechatronics
CHAPTER
Ketema Bobe
Department of Mechanical Engineering
2 September 2023

Mechatronics
What is
Mechatronics?
4
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What is Mechatronics?
Mechatronics is the synergistic combination of mechanical
engineering (“mecha” for mechanisms), electronic engineering
(“tronics” for electronics), and software engineering.
Mechatronics is the field of study concerned with the design,
selection, analysis and control of systems that
mechanical elements with electronic components,
combine
including
computers &/or microcontrollers.
The mechatronics field is not simply the
sum of these three major areas, but rather the
field defined as the intersection of these
areas when taken in the context of systems
design.
Mechatronics may alternatively be referred to as “electromechanical
systems.” 5
2 September 2023

Historical Background
Mechatronics: a concept of Japanese origin, 1970’s. This concept
applicable in 1980’s to produce industrial robots.
The Japanese were the first to recognize the limitations of
traditional mechanical engineering and introduced the term
“Mechatronics” to mean an integrative multidisciplinary approach
for design of mechanical systems and processes.
Virtually every modern electromechanical system has an
embedded computer controller. Therefore, computer hardware and
software issues (in terms of their application to the control of
electromechanical systems) are part of the field of mechatronics.
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Evolution of Mechtronic Systems
The development of mechatronics has gone through three stages.
The first stage corresponds to the years when this term was
introduced. During this stage, technologies used in mechatronics
systems developed rather independently and individually.
During the second stage, i.e., with the beginning of the eighties, a
synergistic integration of different technologies started taking
place. For example: Optoelectronics (i.e. an integration of optics
and electronics). The concept of hardware/software co-design also
started in those years.
The third and the last stage can also be considered as the
beginning of the mechatronics age since early nineties.
8
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Contd…
Important achievement of the third stage
Increased use of computational intelligence in mechatronic
products and systems. It is due to this development that we
can now talk about Machine Intelligence Quotient (MIQ).
It is the possibility of miniaturization of components; in the
form of micro actuators and micro sensors (i.e. micro
mechatronics).
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Contd…
Significance of Mechatronics
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Significance of Mechatronics
The purpose of this interdisciplinary engineering field is
Ability to increase competitiveness of the product
through use of technology.
It automata from an engineering perspective.
It control advanced hybrid systems
Support and enable development of new product
High levels of precision and reliability (Enhance existing
products)
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Characteristics of Mechatronic Systems
Since Mechatronics is not just a marriage of electrical and
mechanical systems and is more than just a control system; it is a
complete integration all of them,
They are generally complex systems with high levels of
integration.
They have more functionality than conventional systems.
Functionality is transferred from the mechanical to the
electronic and software domain.
They are based on the development of some of real-time
system architecture, often involving distributed and devolved
intelligence.
Operation at the system level is generally transparent to the
user.
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The Why of Mechatronics
Mechatronics system designs can often leads to
L
„ow volume
M
„ore variety „
Lower cost of production
H
„igher levels of flexibility
Reduced lead time in manufacture „
Automation in manufacturing and assembly
Lower maintenance cost
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Contd…
Application of Mechatronics
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Application of Mechatronics
Automotive
Aerospace
Telecommunication
Computer Hardware and Software
Medical/ Biomedical application
Home application
Manufacturing (Robotics and Automated)application
Defense application
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Contd…
A typical example of a Mechatronic System
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Contd…
An office copy machine consists of analog and digital
circuits, sensors, actuators and microprocessors.
Analog circuits control the lamp, heater and other power
circuits in the machine.
Digital circuits controls the digital displays, indicator
lights, buttons and switches forming the user interface.
Optical sensors and micro switches detects the presence
or absence of the paper, its proper positioning and
whether or not doors and latches are in their correct
positions.
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Contd…
include encoders used to track the motor
Other sensors
rotation.
Actuators include servo and stepper motors that load and
transport the paper, turn the drum and index the sorter.
Microprocessors coordinate all the functions in the machine
Scanner
Computer
disk drive
Exhibits quick response,
precision, and robustness
Fax
Photocopy
machine
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Contd…
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Contd…
Clothes
washer
 Water temperature
 Load size
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Contd…
Smoke Detector System
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Contd…
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Contd…
a)Vehicle application area
Safety
 Airbag system
Anti-lock breaking system
Electronic stability controls
Comfort
 Door locks
Key less entry system
Heating system controls
Seat positioning controls
Power train
 Engine control
Fuel pump control
Fuel sensing controls
Gearbox controls
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Contd…
Door
System/Module-
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Contd…
b)High Speed Trains
•Train Position and Velocity
JR-Maglev
Top Speed: 574 km/h (357
mph) Country: Japan
constantly monitored from
main command center.
•Error margin in scheduling
no more than 30 seconds
•Fastest trains use magnetic levitation
Transrapid
Top Speed: 550 km/h (340
mph) Country: German
Magnetic Levitation
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Contd…
Advantages
•Simple and intuitive personal transportation
device
c) Segway
Systems Uses
•Tilt and pressure sensors
•Microcontroller
•Motors
•Onboard power source
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Contd…
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Contd…
29
Chapter 1, Dr. Besufekad Negash
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Contd…
Military Applications
•Advanced technology is making
our soldiers safer.
•Some planes can now be flown
remotely.
Unmanned AerialVehicle
Stealth Bomber
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Contd…
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Contd…
 Vacuum cleaner
 Assisting solders in combat fields
 Delivering food and medicine in hospitals
 Operate in unstructured environments
Wheelchair
Vacuum cleaner
Obstacle avoiding mobile
robot
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Contd…
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Contd…
Prosthetics
Arms, Legs, and other body parts can be replaced with
electromechanical ones.
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Contd…
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Contd…
different
Automatically changes cushioning in shoe for
running styles and conditions for improved comfort
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Contd…
• Fully automated bending: load sheet metal and the finished
bent parts come out
• Can bend complex shapes
a) CNC Bending
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Contd…
Advantages
• Deliver the highest accuracies
• Can create very complex shapes
b) CNC Machining
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Contnd
…
c) Industrial robots
Main components: Mechanical arm and controller
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Contd…
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Contd…
System Can
•Carry 340 lb
•Run 4 mph
•Climb, run, and walk
•Move over rough terrain
BigDog
Advantages
•Robot with rough-terrain mobility that
could carry equipment to remote location.
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Contd…
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Contd…
System Can
•Collect specimens
•Has automated onboard lab for
testing specimens
Advantages
•Robot that can travel to other
planets and take measurements
automatically.
Phoenix Mars Lander's
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Contd…
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Contd…
•Used by patients with slow or erratic
heart rates. The pacemaker will set a
normal heart rate when it sees an
irregular heart rhythm.
•Monitors the heart. If heart fibrillates
or stops completely it will shock the
heart at high voltage to restore a
normal heart rhythm.
Pace Maker
Implantable Defibrillation
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Contd…
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Contd…
System Uses
•Proximity sensors
•Control circuitry
•Electromechanical valves
•Independent power source
Advantages
•Reduces spread of germs by making
device hands free
•Reduces wasted water by automatically
turning off when not in use
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Contd…
Advantages
• Reduces spread of germs by making device
hands free
• Reduces wasted materials by controlling how
much is dispensed
Systems Uses
•Motion sensors
•Control circuitry
•Electromechanical actuators
•Independent power source
Soap Dispenser
Paper Towel Dispenser
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Basic Elements of Mechatronics System
system is an integration of the
Generally any Mechatronic
following major components:
 Sensors
 Actuator
 Controller
 The control logic
 Signal Processing
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Design of mechatronic systems
Stages in design process
The need
Analysis of problem
Preparation of Specification
Generation of possible solutions
Selection of a suitable solution
Production of a detailed design
Production of working drawings
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Contd…
Advantages of mechatronics design
High resolution and accuracy
Reduces house hold heating cost
Self calibrating
Flexible design
Environmental friendly
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Chapter Two
Sensors and Actuators
CHAPTER
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Sensors and Actuators
Contents
Sensor and transducer
Terminologies
Displacement, position and proximate
Velocity and motion
Force and fluid pressure
Liquid flow and level
Temperature
Light sensor
Selection of sensor
Inputting data by switches
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/
Sensors and Transducer
69
is a device that produces an output signal for the purpose of
sensing of a physical phenomenon.
It is used for an input device that provides a usable output in
response to a specified physical input.
For example, a thermocouple is a sensor that converts a temperature
difference into an electrical output.
is a device that converts a signal from one form to a
different physical form.
It is a device that converts one type of energy to another.
Energy types include (but are not limited to) electrical,
mechanical, electromagnetic (including light), chemical,
2 September 2023

Terminologies
generally
filtering,
includes
electrical
a front-end preprocessing, which
functions such as signal amplification,
isolation, and multiplexing.
In addition, many transducers require excitation currents or
voltages, bridge completion, linearization, or high amplification
for proper and accurate operation.
Charge amplifiers, lock-in amplifiers, power amplifiers,
switching amplifiers, linear amplifiers, tracking filters, low-
pass filters, high-pass filters, and notch filters are some of the
signal-conditioning devices used in mechatronics systems.
55
Chapter 2, Dr. Besufekad Negash
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Contd…
- it is the limits between which the input can vary.
For example – Load cell for the measurement of forces might have
a range of 0-50 kN.
- the difference between the result of the measurement and the
true value of the quantity being measured.
Error= Measured value – True value
- is the extent to which the value indicated by a
measurement system might be wrong. It is the summation
of all possible errors that are likely to occur, as well as
the accuracy to which the transducer has been calibrated.
For Example – A sensor might be specified as having an accuracy of
+5% of full range output. Given: Temp Range 0-200 °C. Reading could be
within + 10 °C of the true reading.
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Contd…
- is the relationship indicating how much output you get
per unit input, ie. Output/input.
For example: A resistance thermometer may have sensitivity of 0.5
ohms/ °C
Sensitivity is the ability of the measuring instrument to respond to
changes in the measured quantity. It is also the ratio of the change of
output to change of input.
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Contd…
Hysteresis Error
The error of a measurement is the difference between the result of
the measurement and the true value of the quantity being measured.
- is the maximum difference in output for increasing
and decreasing values.
Hysteresis is an error caused by when
the measured property reverses
direction, but there is some finite lag in
time for the sensor to respond, creating
a different offset error in one direction
than in the other.
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Contd…
Fig. Some source of error: (a) Nonlinearity and (b) Hysteresis
59
The error associated in the deviation from linearity between the
input and the output. The error is quoted as the percentage of the
full range output.
Nonlinearity and hysteresis
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Contd…
the repeatability of the transducer is its ability to give
the same output for repeated applications of the same
input value.
For example: Angular velocity => repeatability + 0.01% of the full
range at a particular angular velocity.
the ability to give the same output when used to
measure a constant and is measured on a number of
occasions.
the stability of a transducer is its ability to give the same
output when used to measure a constant input over a
period of time.
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Contd…
is often used to describe the change in output that occurs over
time.
The drift expressed as a percentage of the full range output.
The term zero drift is used for the changes that occur in
output when there is zero input.
is the range of input values for which
there is no output.
For example: bearing friction in a flow meter using a rotor might
mean that there is no output until the input has
reached a particular velocity threshold.
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Contd…
The resolution of a sensor is the smallest change it can
detect in the quantity that it is measuring.
The resolution is related to the precision which the
measurement is made.
For example: a scanning tunneling probe (a fine tip near a surface
collects an electron tunneling current) can resolve
atoms and molecules
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Sensors and transducers
Displacement, position and proximity
Potentiometer
Strain-gauged element
C
„apacitive element „
Linear variable differential transformers „
Eddy current proximity sensors „
Inductive proximity switch
Optical encoders
P
„neumatic sensors
P
„roximity switches (magnetic)
Hall effect sensors
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Sensors
Velocity and motion
Incremental encoder
Tachogenerator „
„Pyroelectric sensors „
„
Force „
Strain gauge load cell
Fluid pressure „
D
„iaphragm pressure gauge
C
„apsules, bellows, pressure tubes
Piezoelectric sensors „
Tactile sensor
Liquid flow „
Orifice plate „
Turbine meter
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Sensors
L
„iquid level „
Floats „
Differential pressure
Temperature
B
„imetallic strips „
Resistance temperature detectors „
Thermistors „
Thermo-diodes and transistors „
Thermocouples
Light sensors
P
„hoto diodes
Photo resistors
P
„hoto transistor
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Contd…
Displacement sensor- is measure the distance between the present
position of the target and the previously
recorded position.
- how much the object has been moved
Position sensor- is used for a sensor that gives a measure of the
distance between a reference point and the
current location of the target
- position of an object with a reference point
Proximity- Form of position sensors, it detects when an object has
moved
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Contd…
Two groups
Linear
Angular
Linear displacement sensors might be used to monitor the
thickness or other dimensions of sheet materials, separation of
rollers, the position or presence of a part, the size of a part.
Angular displacement methods might be used to monitor the
angular displacement of shafts.
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Contd…
Application: Location and position of object on a conveyor
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Contd…
 Two basic types of displacement / position sensor:-
1. Contact devices
• Limit switches
• Resistive position transducers
2. Non-contact devices
• Magnetic sensors, including Hall effect and magneto-resistive
sensors
• Ultrasonic sensors
• Proximity sensors
• Photoelectric sensors
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Measuring Displacement
99
• With the supply voltage (Vs), the output voltage (V
o) will vary
between zero and the supply voltage.
• Displacement is measured based on potential difference
•„Plastic resin embedded with carbon powder
• Potentiometers are very common devices used to measure
displacement. A linear potentiometer is used for linear measurements
and an angular potentiometer is used for angular measurements.
• The linear potentiometer is a device in which the resistance varies as a
function of the position of a slider, shown below.
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Contd…
• It should be noted that the device measuring Vo must have a high
impedance to maintain a linear response and avoid loading error.
•Linear potentiometers can be used to measure displacements as
small as 0.1 to 0.2 in. (2.5 to 5 mm) up to displacements of more than
1 ft.
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Contd…
 The electrical resistance strain gauge is a metal wire, metal foil strip, or
a strip of semiconductor material which is wafer like and can be stuck
into surfaces like a postage stamp.
 When subject to strain, its resistance R changes, the fractional change
in resistance ∆R/R being proportional to the strain E, that is
∆R/R=GE
 Where G, the constant of proportionality, is termed as the gauged
factor.
 The resistance change of a strain gauge is a measurement of the change
in length of the element to which the strain gauge is attached
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Contd…
 Electric-resistance strain gauge
 Metal wire, metal foil strip, a strip of semiconductor material
„
∆R/R= Gε
 G = constant of proportionality, Gauge factor
 G
„ = 2, Calibration based on actual experiments „
 Constantan alloy: copper-nickel (55-45%) alloy
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Contd…
Example: An electrical resistance of 100 ohms and a gauge factor of
2.0. What is the change of resistance ΔR of the gauge
when it is subject to a strain of 0.001.
Answer:
ΔR = R×G × strain
ΔR =100×2.0×0.001
ΔR =0.2 ohms
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Contd…
Strain gauges
• „Deflection or deformation of flexible
elements
• Attach to flexible elements „viz.
cantilevers, pipes, U shaped elements
• „Linear displacement in the order of 1 to
30 mm
•„Nonlinearity error 1% of the full range
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Contd…
Strain Gauge
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Contd…
Monitoring of displacement „
Non-contact type displacement
sensor
C
„= (εrεoA)/d
ε
„r= relative permittivity of
dielectric between the plates
ε„o=permittivity of free space
„
A
= area of overlap „
d = plate separation
Example: T
„
ouch-screen: Apple „
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Contd…
Fig. a Capacitive proximity sensor detects a change
in capacitance incurred by the presence of a seal ring
target
80
Fig. Presence of the metal target reduce the metal target
reduces the effective distance between electrodes (by the
factor t), resulting in an increase in capacitance.
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Contd…
 It is a mechanical displacement transducer.
 It gives an a.c. voltage output proportional to the distance of the
transformer core to the windings.
 The LVDT is a mutual-inductance device with three coils and a core An
external a.c. power source energizes the central coil and the two-
identical secondary coils connected in series in such a way that their
outputs oppose each other.
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Contd…
Fig. LVDT 82
A magnetic core is moved through the central tube as a result of
displacement being monitored. However when the core is displaced
from the central position there is a greater amount of magnetic core
in one coil than the other.
A greater displacement means even more core in one coil than the
other, the output, the difference between the emf increases, the
greater the displacement being monitored.
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Contd…
A greater displacement means even more core in one coil than the
other, the output, the difference between the emf increases, the
greater the displacement being monitored.
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Contd…
Primary transducer „
Operating range ±2 to ±400 mm „
Non-linearity error ±0.25% of
full range „
Absolute position sensor „
Good repeatability and
reproducibility „
Highly reliable
N
„on-contact, no friction or
sliding „
Completely sealed „
 Servomechanisms, automated
measurement in machine tools „
 Works with phase sensitive
demodulator and low pass filter
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Contd…
 Detection of non-magnetic conductive material
 Relatively inexpensive
 Small in size
High reliability
High sensitivity for small displacements
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Contd…
Coil wound on acore
close to a metallic object
inductance changes metallic object
inductance changes
monitored by a resonant circuit
triggers a switch
Detection of metallic objects
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Contd…
An encoder is a device that provides digital output as a result of
linear and angular displacement.
Position encoders are of two types:
1.Incremental
2.Absolute
Incremental encoders : Detect changes in rotation from some datum
while the absolute encoders give the actual angular position.
Absolute encoder
Incremental encoder
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Contd…
Digital output as result of linear / angular displacement angular
displacement
Number of pulses proportional to angular displacement
Angular position = number of pulses from the datum position
Sequential output of the sensor = No in the binary code
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Contd…
D
„isplacement or proximity can be transformed into change in air
pressure
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Contd…
 Micro switches: electrical contact type switches
 Conveyor belts
 Reed switch: non-contact magnetic switch
 Widely used in checking the closure of doors
 Can be used with tachometers Reed Switch
Lever operated Roller operated Cam operated
 Output : on or off
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Contd…
„When a beam of charge particles
passes through a magnetic field,
forces act on the particles and
the beam is deflected from its
straight line path.
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Contd…
Displacement, position a well as proximity detection „
Needs necessary signal conditioning circuitry
A
„dvantages
C
„an be operated at 100 kHz „
Non-contact „
Immune to environment contaminants „
Can be used under severe conditions
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Contd…
This can be used for measuring angular velocity, number of pulses
produced per second being determined.
Used to measure angular velocity. It is essentially a small electric
generator, consisting of coil mounted in magnetic field .when the coil
rotates an alternating emf is induced in the coil, the size of the
maximum emf being a measure of the angular velocity. when used
with a commutator a dc output can be obtained which is a measure of
the angular velocity.
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L
„ithium tantalate, crystal material
Generates charge in response to heat
flow „
Material > heat + electric field >
electrical dipoles line up > polarization>
retains the polarization after cooling „
Such polarized material > infrared
radiation > rise in temp > reduces the
polarization „
Pyroelectric sensor
polarized material +
= pyroelectric
thin metal film
electrodes on opposite faces
∆q= kp∆T 95
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Contd…
Force: The measurement of the interaction between bodies.
The most commonly used sensors are generally based on either
piezoelectric quartz crystal or strain gage sensing elements.
Technology Fundamentals
Quartz force sensors suited for the measurement of dynamic
oscillating forces, impact, or high speed compression/tension
forces.
The basic design utilizes the piezoelectric principle, where applied
mechanical stresses are converted into an electrostatic charge that
accumulates on the surface of the crystal.
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Devices to measure these small changes in dimensions are called
strain gages.
Strain Gauge Load Cell –use of electrical resistance to monitor the
strain produced in some member when stretched, compressed or bent.
S
„pring balance
S
„train gauge load cell
Electrical resistance „
Forces up to about 10 MN „
Non-linearity error ±0.03%
Repeatabilityerror±002
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Technology Fundamentals
Sensors based on foil strain gage
technology are ideally designed for the
precise measurement of a static weight or
force.
The applied input is translated into a
voltage by the resistance change in the
strain gauges.
The amount of change in resistance
indicates the magnitude of deformation in
the transducer structure and hence the load
that is applied.
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a) Metal wire b) Metal foil c) Semiconductor
A strain gauge, a device whose electrical resistance varies in
proportion to the amount of strain in the device. The most widely
used gauge is the bonded metallic strain gauge. 99
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Contd…
 Two common arrangements of the three strain gages are:
 Rectangular rosette
 Equiangular rosette
 In rectangular rosette, the gages are placed at angles of 0, 45 and
90 degrees.
 In equiangular rosette, the gages are arranged at 0, 60 and 120
degrees.
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Contd…
In industrial processes, chemical
petroleum, power industry
E
„lastic deformation of diaphragms,
capsules, bellows „
Absolute pressure measurement
Use of strain gauges „
S
„ilicon diaphragms with doped
strain gauges Capsule (more sensitive
than diaphgm)
Bellows
Flat diaphragm
101
Corrugated diaphragm
2 September 2023

Contd…
Stretched or compressed generates electric charge > voltage „
Ionic crystals
q = kx= SF „
Measurement of forces, pressure, acceleration
102
2 September 2023

Contd…
Pressure sensor „
Finger tips of robot hands „
Touch screen devices
PVDF piezoelectric polyvinylidene fluoride
103
2 September 2023

Contd…
Based on measurement of pressure
drop „
Quantity of fluid flow is proportional
to square root of pressure difference
O
„rifice plate : simple, cheap with no
moving parts „
Does not work with slurries „
Accuracy ±1.5%, nonlinear „
Turbine meter: multi bladed rotor
and a magnetic pick-up „
Accuracy ±0.3%, expensive
104
2 September 2023

Contd…
D
„ irect method : monitoring the
position of liquid surface, floats „
Indirect method : measurement of
some variable related to the height,
weight, pressure difference
105
2 September 2023

Contd…
Bimetallic strips „
Metals with different coefficients of
expansion
Temperature controlling switches
106
2 September 2023

Contd…
 Mixtures of metal oxides, chromium, cobalt, iron, manganese and
nickel : semi conductors „
 Resistance decreases in a very nonlinear manner with increase in
temperature „
Largechange in resistance per degree change in temperature
Highly nonlinear
107
2 September 2023

Contd…
T
„wo metals held together, potential difference (PD) occurs at the
junction
PD depends upon metals and temperature „
Complete circuit involving two junctions „
Reference junction 0⁰C (Ice and water)
Compensation circuit, to compensate emf by dropping voltage
across a resistance thermometer element „
Use of sheath, low response time
108
2 September 2023

Selection of sensors
Nature of measurement required „
Variable V
„ariable „
Nominal value „
Range
Accuracy
Speed „
Reliability
Environmental conditions
Nature of output, decides signal conditioning requirement „
Maintainability L
„ife L
„ife „
Power supply requirements „
Ruggedness „
Availability „
Cost
109
2 September 2023

Chapter Three
Signal Conditioning
CHAPTER
3
2 September 2023

• Signal conditioning circuits are used to process
the output signal from sensors of a measurement
system to be suitable for the next stage of
operation

 The sensing element converts the non-electrical signal (e.g.
temperature) into electrical signals (e.g. voltage, current,
resistance, capacitance etc.).
 The job of the signal conditioning element is to convert the
variation of electrical signal into a voltage level suitable for
further processing.
 The next stage is the signal processing element.
 It takes the output of the signal conditioning element and
converts into a form more suitable for presentation and
other uses (display, recording, feedback control etc.).
 Analog-to-digital converters, linearization circuits etc. fall
under the category of signal processing circuits.

• The success of the design of any measurement
system depends heavily on the design and
performance of the signal conditioning circuits.
• Even a costly and accurate transducer may fail to
deliver good performance if the signal conditioning
circuit is not designed properly.
• Nowadays, many commercial sensors often have in-
built signal conditioning circuit.
• This arrangement can overcome the problem of
incompatibility between the sensing element and the
signal conditioning circuit.

The function of the signal conditioning circuits
include the following items:
 Signal amplification
 Filtering
 Interfacing with Data Acquisition (ADC)
 Protection(Zener & photo isolation),
 Linearization,
 Current – Voltage change circuits,
 Resistance change circuits (Wheatstone bridge),
 Error compensation

 Filtering
 we can also use filters to reject unwanted noise within a certain
frequency range.
 Many systems will exhibit 60 Hz periodic noise components from
sources such as power supplies or machinery.
 Many signal conditioners include low pass noise filters
to remove unwanted noise, an extra precaution is to use
software averaging to remove additional noise.

 Low pass filters on our signal conditioning circuitry can
eliminate unwanted high-frequency components.
 However, be sure to select the filter bandwidth carefully so
that we do not affect the time response of our signals.
 Software averaging is a simple and effective technique of
digitally filtering acquired readings; for every data point
you need, the Data Acquisition (DAQ) system acquires and
averages many voltage readings.
 For example, a common approach is to acquire 100 points
and average those points for each measurement you need.
 For slower applications in which you can oversample in
this way, averaging is a very effective noise filtering
technique.

Operational Amplifiers
 Many sensors develop extremely low-level output signals.
 The signals are usually too small for applying directly to
low-gain, multi flexed data acquisition system inputs, so
some amplification is necessary.
 Two common examples of low-level sensors are
thermocouples and strain-gage bridges that typically deliver
full-scale outputs of less than 50 Mv

Amplification
 Unwanted noise can play havoc with the measurement
accuracy of system.
 The effects of system noise on the measurements can be
extreme if we are not careful.
 An amplifier, located directly on the in external signal
conditioners and can apply gain to the small signal before
the Analogue to Digital Converter (ADC) converts the
signal to a digital value.
 Boosting the input signal uses as much of the ADC input
range as possible.

Isolation
 Improper grounding of the DAQ system is the most common
cause of measurement problems and damaged DAQ boards.
 Isolated signal conditioners can prevent most of these problems
by passing the signal from its source to the measurement device
without physical connection.
 Isolation breaks ground loops, rejects high common-mode
voltages, and protects expensive DAQ instrumentation.
 Common methods for circuit isolation include using optical,
magnetic, or capacitive isolators.

 Magnetic and capacitive isolators modulate the signal to convert
it from a voltage to a frequency.
 The frequency can then be transmitted across a transformer or
capacitor without a direct physical connection before being
converted back to a voltage value.
 When you connect your sensor or equipment ground to your
DAQ system, you will see any potential difference in the
grounds on both inputs to your DAQ system.
 This voltage is referred to as common-mode voltage.
 Most data acquisition systems use a number of different types of
circuits to amplify the signal before processing.

 Modern analog circuits intended for these data acquisition
systems comprise basic integrated operational amplifiers,
which are configured easily to amplify or buffer signals.
 Integrated operational amplifiers contain many circuit
components, but are typically portrayed on schematic
diagrams as a simple logical functional block.
 A few external resistors and capacitors determine how they
function in the system.
 Their extreme versatility makes them the universal analog
building block for signal conditioning.

Chapter Four
MECHANICAL ACTUATION
SYSTEMS
CHAPTER
2 September 2023

M e c h a n i c a l a c t u a t i o n s y s t e m
 Mechanical system involving:
 Linkages
 Cams
 Gears
 ratchet and pawl
 belt and chain drives

Cont.…
 Provide function as:
 Motion converters
 rotational to linear
 Force amplification
 lever
 Change of speed
• gears
 Transfer of rotation axis
 timing belt
 Particular types of motion
 quick return mechanism, cam

Types of motion
 Translational, rotational and its combination
 Degree of freedom, dof
 dof = 6 – number of constrain
Cont.…

Ty p e s o f m o t i o n
 Translational, rotational and its combination
 Degree of freedom, dof
 dof = 6 – number of constrain
 For planar
dof = 3(N-1) – 2L
where:
N = number of link
L = number of join
Cont.…

Kinematic chains
 A link is part of a mechanism
 A joint is a connection between link
 Kinematic chain is a sequence of
link and joints
Cont.…

K i n e m a t i c c h a i n s
 Open loop kinematic chain
Cont.…

K i n e m a t i c c h a i n
 Slider crank mechanism
Cont.…

 The four bar chain
 Grashoff theorem
 Lmax + Lmin less than or equal to La + Lb
 for one link to rotate 360 deg
Double crank
Double lever Lever crank
Cont.…

Example
Cont.…

C a m s
 Rotates to provide reciprocating motion to the follower
Cont.…

G e n e v a w h e e l
Lower Wheel
Upper Wheel
Upper wheel axis of rotation
Lower wheel axis of rotation
Driving pin
 Mechanism is used for achieving intermittent motions.
 The component has two wheels; upper & lower
 Continuous rotational movement of the lower wheel
 Intermittent motion of the upper wheel; rotates step-wise

G e a r t r a i n s
 Used to change speed or torque of rotating device
Cont.…

G e a r t r a i n s
• G = A / B = dB / dA= B / A
G = A / B x B / C = A / C
Cont.…

Epycylic gear train
 Consists of groups of gears
 3 possibility of gear ratios
Cont.…

Ratchet and pawl
 Used to lock a mechanism when its holding a load
Cont.…

B e l t a n d c h a i n d r i v e s
 Torque on A, A = (T1 - T2) rA
 Torque on B, B = (T1 - T2) rB
 Power = (T1 - T2)v
–where belt speed v = A rA
Cont.…

B e l t a n d c h a i n d r i v e s
 Reversing drive
Cont.…

STATIC CHARACTERISTICS OF DEVICE
 As mentioned earlier, the static characteristics are defined
for the instruments which measure the quantities which do
not vary with time.
 The various static characteristics are :-
1. ACCURACY
2. PRECISION
3. RESOLUTION
4. ERROR
5. SENSITIVITY
6. THRESHOLD
7. REPRODUCIBILITY
8. ZERO DRIFT
9. STABILITY
10.LINEARITY

1. Accuracy
 It is the degree of closeness which the instrument reading approaches to
true value of the quantity to be measured.
 It denotes the extent to which we approach the actual value of the quantity.
 It indicates the ability of instrument to indicate the true value of the quantity.
The accuracy can be expressed in the following ways
i. Accuracy as Percentage of Full Scale Reading:
 In case of instruments having uniform scale, the accuracy can be expressed
as percentage of full scale reading.
E.g. The accuracy of an instrument having full scale reading of 50 units may
be
expressed as ± 0.1 % of full scale reading. From this accuracy indication,
practically
accuracy is expressed in terms of limits of error. So for the accuracy limits
specified above, there will be ± 0.05 units error in. any measurement
ii. Accuracy as Percentage of True Value:-
 This is the best method of specifying the accuracy.
 It is to be specified in terms of the true value of quantity being measured.
 For example, it can be specified as ± 0.1% of true value.
 This indicates that in such cases, as readings get smaller, error also gets

iii. Accuracy as Percentage of Scale Span:-
 For an instrument, if amax is the maximum point for which scale is calibrated,
i.e. full scale reading and amin is the lowest reading on scale.
 Then (amax - amin) is called scale span or span of the instrument.
 Accuracy of the instrument can be specified as percent of such scale span.
 Thus for an instrument having range from 25 units to 225 units, it can be
specified as ± 0.2 % of the span i.e.± [(0.2/l00)x (225 - 25)] which is ± 0.4 units
error in any measurement.
iv. Point Accuracy :
 Accuracy is specified at only one particular point of scale.
 It does not give any information about the accuracy at any other point on the
scale. Therefore, general accuracy of an instrument cannot be specified, in this
manner. But the general accuracy can be specified by providing a table of the
point accuracy values calculated at various points throughout the entire range of
instrument.
2. PRECISION: It is the measure of consistency or repeatability of
measurement.
 Precision means sharply or clearly defined and the readings agree among
themselves. But there is no guarantee that readings are accurate.

Example 1 The table shows the set of 5 measurements recorded in a
laboratory.
Calculate the precision of the 3rd measurement
3 Error: The most important static characteristics of an instrument is its
accuracy, which is generally expressed in terms of the error called static
error.
The algebraic difference between the indicated value and the true value
of the quantity to be measured is called an error.
Mathematically it can be expressed as

154
 In this expression, the error denoted as e is also called absolute error.
 The absolute error does not indicate precisely the accuracy of the
measurement.
For example, absolute error of ±1V is negligible when the voltage to be
measured is of the order of 1000V but the same error of ±1 V becomes
significant when the voltage under measurement is 5V or so. Hence,
generally instead of specifying absolute error, the relative or percentage
error is specified.

Example 2: The expected value of the voltage to be measured is 150 V.
However, the measurement gives a value of 149 V. Calculate (i) Absolute error;
(ii) Percentage error; (iii) Relative accuracy; (iv) Percentage accuracy and (v)
Error expressed as percentage of full scale reading, if the scale range is 0-200 V.

SENSITIVITY:
Denotes the smallest change in the measured variable to which the
instrument responds. It is defined as the ratio of the changes in the output
of an instrument to a change in the value of the quantity to be measured.
Mathematically it is expressed as,
 The sensitivity is always expressed by the manufacturers as the ratio
of the magnitude of quantity being measured to the magnitude of the
response.
 Actually, This definition is the reciprocal of the sensitivity is called
inverse sensitivity or deflection factor.

Example 3: A particular ammeter requires a change of 2A in its coil to
produce a change in deflection of the pointer by 5mm. Determine its
sensitivity and deflection factor.
Solution : The input is current while output is deflection.
Sensitivity= change in output / change in input = 5 mm /2A . = 2.5 mm / I A

 Statistical Analysis: Out of the various possible errors, the random
errors can not be determined in the ordinary process of measurements.
Such random errors are treated mathematically.
 The mathematical analysis of the various measurements is called
statistical analysis of the data.
 For such statistical analysis, the same reading is taken number of times,
generally using different observers, different instruments and by different
ways of measurement.
 The statistical analysis helps to determine analytically the uncertainty of
the final test results.
 Arithmetic Mean and Median: When the number of readings of the
same measurement are taken, the most likely value from the set of
measured variable values is the arithmetic mean of the number of
readings taken.
 The arithmetic mean value can be obtained mathematically as,

 The approximation with the help of mean value is valid for all data sets if
the measurement errors are distributed equally. about the zero error line.
 This means the positive errors are balanced in quantity and magnitude by
the negative errors.
 This mean is very close to true value, if number of readings is very large.
But when the number of readings is large, calculation of mean value is
complicated.
 In such a case, a median value is obtained which is a close approximation
to the arithmetic mean value.
 For a set of measurements xl, x2, x3…….. xn written down in the
ascending order of magnitudes, the median value is given by,
 Thus, for a set of eleven measurements xl, x2, ..... xll' the median
value is x(11+l)/2 = x6
 For the even number of data values, the median value is midway
between the centre two values.
 For twelve measurements xl, ,x2, to xl2 the median value is given by (x6
+x7) /2

 Deviation from Mean
 The deviation tells us about the departure of a given reading from the
arithmetic mean of the data set. This is denoted as d and calculated for
each reading as
160
 Key Point: This departure of reading from the arithmetic mean may be
positive or negative.
 Average Deviation: The average deviation is defined as the sum of the
absolute values of deviations divided by the number of readings.
 This is also called mean deviation.
 Standard Deviation:-The amount by /which the n measurement values
are spread about the mean is expressed by a standard deviation. It is also
called root mean square deviation.
 The standard deviation is defined as the square root of the sum of the
individual deviations squared, divided by the number of readings.

 Variance: The variance means mean square deviation, so it is the square of
the standard deviation. It is denoted as V .
in practice for small number of readings less than 20, the denominator in
equation (4a) is expressed as n - 1 rather than n.

1. Problem: Find the mean, median, standard deviation and variance of
the measured data. The following 13 observations are recorded when
measuring a temperature of a same quantity.1089, 1092, 1094, 1095,
1098, 1100, 1104, 1105, 1107, 1108, 1110, 1112, 1115.
 Least square fit of experimental data in measurement systems
Where: Yi is the linearized output, yi is the non-linear output.
Substitute a & b values into Y = axi +b, which is then called the least-squares
best fit.

a=6.476
b=-0.0291
y=6.476x-0.0291

SENSITIVITY: Sensitivity is the ratio of change in magnitude of the output
to the change in magnitude of the measured • Sensitivity =
D(output)/D(input)
 High Sensitivity is desirable in the Instruments.
 Highly sensitive instruments produce less error.
LINEARITY; The maximum deviation of calibration curve from straight line
drawn between no load and full load output.
 It is expressed as a percentage of full scale output or as a percentage of
actual reading. % of linearity= (Max. deviation/ Full scale reading) X100
 It is highly desirable that the measurement system has a linear
relationship between input and output means that the change in output is
proportional to the change in the value of the measured.
 Deviation from true linearity is called linearity error.
 The input and output relationship of a linear transducer can be
represented by the following equation: y = mx + c where y is the output
of transducer, x is the input of transducer, m is the slope of curve
(transfer function), c is the offset.
 Often, the straight line approach is used for certain range of operation for

Problem 1. In an experiment, the following output voltages are obtained
when the displacements are measured by a displacement sensor. Obtain the
best linear relation in accordance with a least square analysis and estimate
(i) output voltage when a displacement of 6.5 mm is measured.
(ii) Sensitivity of the sensor
(iii) % of Non-linearity of the sensor
(iv) Calculate the mean deviation and standard deviation of the Output
Voltage data.
Problem 2. In an experiment, the following output voltages are obtained
when the displacements are measured by a displacement sensor. Obtain the
best linear relation in accordance with a least square analysis and estimate
output voltage when a displacement of 5.5 cm is measured. Calculate the
mean deviation and standard deviation of the Voltage-data.

Limiting Errors:
 The manufacturers specify the accuracy of the instruments within a certain
percentage of full scale reading.
 The components like the resistor, inductor, capacitor are guaranteed to be
within a certain percentage of rated value.
 This percentage indicates the deviations from the nominal or specified value
of the particular quantity.
 These deviations from the specified value are called Limiting Errors. These
are also called Guarantee Errors.
 Example Resistor is specified by the manufacturer as 4.7 k with a
tolerance of ± 5 % then the actual value of the resistance is guaranteed to be
within the limits.
 R = 4.7 k ± (5 % of 4.7 k ) = 4.7 k ± 0.235 k = 4.935 k and 4.465
k .
 Thus the actual value with the limiting error can be expressed
mathematically a

• Relative Limiting Error:
• This is also called fractional
error.
• It is the ratio of the error to the
specified magnitude of a
quantity.
e = relative limiting error
From the above equation, we can
write
• The percentage relative limiting
error is expressed as
 The relative limiting error can be
also be expressed as,

Combination of Quantities with
Limiting Errors
 When the two quantities are
combined, each having limiting
error, then it is necessary to
calculate the overall limiting error.
 Let us consider the various
combinations of two quantities and
methods to obtain the
corresponding limiting error.

Key Point: The total limiting error is sum of the products obtained by
multiplying the individual limiting error by the ratio of each term to the
resultant function.

• Let
 The result is same as that obtained
for the product.
 If there is product or division of
more than two quantities, then,
If the result is the product of
different powers of two quantities i.e,

Example: The r.m.s. current
passing through a resistor of
120±0.5 ohms is 2 ±0.02 A.
Calculate the limiting error in the
value of power dissipation.
 el= limiting error while the limiting
error due to resistance is e2.
• As power is the product of I2 and R,
the resultant error is the sum of the
2
• Example: Three resistances have
the following ratings
;R1=15±5%; R2=33 n ± 2 %;
R3 = 75  ± 5 %.
• Determine the magnitude and
limiting error in ohms, if the
resistances are connected in series.
Also obtain percentage relative
limiting error in the resultant.

Solution : a) Errors as limiting
errors
Example: Voltmeter reads 111.5V.
The error taken from an error curve is
5.3 %. Find the true value of the
voltage.
Thus, the resultant is 123 with the
limiting error of 5.16 . Thus, δPT=
5.16 and RT=123.Hence the %
relative limiting error is,
Example: In a series circuit of two
resistances, the voltage across R1is
150 ±2V and that across R2 is
75±3V. Determine the percentage
error in the total voltage across the
combination,
a) Considering the errors in two

Example: Three resistances are
specified as :R1= 200Ω ±5%, R2=
100Ω±5%, R3=50Ω ±5%.
Determine the magnitude of the
resultant resistance and the
limiting error in percentage and in
ohms if the resistances are
connected in series.
Solution : The resistances are in
series

Example Current was measured during
a test as 20.5 A, flowing in a resistor of
0.2Ω . It was found that the ammeter
reading was low by 1.3 % while the
resistance value was high by 0.5 %.
Find the true power as a percentage of
the power that was originally
calculated.
Solution: The ammeter reading is
20.5A
But true reading is higher by 1.3 % as
ammeter is showing low reading.
Example : A particular bridge gives
the value of the unknown resistance
as,

 Basic D.C. Ammeter
 The basic D.C ammeter is
galvanometer.
 The coil winding of a basic
movement is very small and light
and hence it can carry very small
currents.
 For large currents, the major part
of current is required to be
bypassed using a resistance called
shunt. It is shown in the Fig.
below.
 Let
Fig. Basic d.c, ammeter

 As the two resistances Rsh and Rm
are in parallel, the voltage drop
across them is same.
The m is called multiplying power
of the shunt and defined as the ratio
of total current to the current
through the coil. It can be expressed
as,
Example 1: A 2mA meter with an
internal resistance of 100Ω is to be
converted to 0-150 mA ammeter.
Calculate the value of the shunt
resistance required.
Solution: Given values are,
.

Example 2. A moving coil
ammeter has fixed shunt of 0.01Ω.
With a coil resistance of 750 Ω and
a voltage drop of 400 mV across it,
the full scale deflection is
obtained.
a) Calculate the current through
shunt.
b) Calculate the resistance of meter
to give full scale deflection if
the shunted current is 50 A.
Solution:(a) The drop across the
shunt is same as drop across the
coil.
b) The voltage across shunt for
shunted current of 50 A is,
 For this voltage the meter
should give full scale deflection.
In first case, the current through
meter for full scale deflection
was,
 The same 1m must flow for new
voltage across the meter of 0.5
V.
 This is the resistance of the
meter required for 50 A shunted
current to give full scale
deflection.

 Basic D.C. Voltmeter :The basic d.c. voltmeter is galvanometer. The
resistance is required to be connected in series with the basic meter to use it
as a voltmeter.
 This series resistance is called a multiplier. The main function of the
multiplier is to limit the current through the basic meter so that the meter
current does not exceed the full scale deflection value.
 The voltmeter measures the voltage across the two points of a circuit or a
voltage across a circuit component. The voltmeter must be connected across
the two points or a component, to measure the potential difference, with the
proper polarity. The multiplier resistance can be calculated as :
Rm = Internal resistance of coil i.e. meter
Rs = Series multiplier resistance
Im =Full scale deflection current
V = Full range voltage to be measured
Example :A moving coil instrument gives a full scale deflection for a
current of 20mA with a potential difference of 200mV across it. Calculate :
i) Shunt required to use it as an ammeter to get a range of 0- 200 A.
ii) ii) Multiplier required to use it as a voltmeter of range 0- 500V.

Multi range Voltmeters
The range of the basic d.c. voltmeter can be extended by using number of
multipliers and a selector switch. Such a meter is called multi range
voltmeter
 The R1, R2, R 3 and R4 are the four
series multipliers. When connected in
series with
the meter, they can give four different
voltage ranges as V1,V2, V3 and V4. The
selector
switch S is multi position switch by

 The mathematical analysis of basic d.c. voltmeter is equally applicable for
such multi range voltmeter.
 Practical Multirange Voltmeter
More practical arrangement of multiplier resistances In this arrangement, the
multipliers are connected in a series string.
 The connections are brought out from the junctions of the resistances. The
selector switch is used to select the required voltage range.
 When the switch S is at position VI' RI + R2 + R 3 + R4 acts as a multiplier
resistance. While when the switch S is at position V4 then the resistance R4
only acts as multiplier resistance. The V4 is the lowest voltage range while
VI is the maximum voltage range. The multiplier resistances can be
calculated as :
 In position V4 , the multiplier is R4 only.
 The total resistance of the circuit is say RT.

Example : A basic galvanometer.
movement with an internal resistance of
50 Q and a full scale deflection current
of 2mA is to be used as a multi range
voltmeter. Design the series string of
multipliers to obtain the voltage ranges
of 0 - 10 V, 0 - 50 V, 0 - 100 V, 0- 500 V

What is PLC?
A PLC is a solid state / industrial computer that performs
discrete or sequential logic in a factory environment.
It was originally developed to replace mechanical relays,
timers, counters.
A sequence of instructions is programmed by the user to the
PLC memory. Its purpose is to monitor crucial process
parameters and adjust process operations accordingly.
2 September 2023
Introduction

History and Origin
Developed to replace relays in the late 1960s
PLC began in the 1970s, and has become the most common
choice for manufacturing controls.
The PLC was invented in response to the needs of the American
automotive manufacturing industry (primarily General motors).
Costs dropped and became popular by 1980s
Now used in many industrial designs
2 September 2023

Programmable Logic Devices (PLD)
Programmable Logic Devices (PLD) - to perform different
control functions, according to the programs written in its
memory, using low level languages of commands.
 Microprocessor, a digital integrated circuit –digital functions
necessary to process information
Microcomputer - uses microprocessor as its central
processing unit and contains all functions of a computer
Programmable Logic Controller (PLC) - to control the
operation of electro-mechanical devices
2 September 2023

Contd…
What is a Microprocessor (MP)?
The word Microprocessor is a combination of two words micro and
processor
In our context processor means a device which processes binary
numbers (0’s and 1’s)
Micro means small
Before the birth of microchip, processors were large discrete
elements
After invention of microchip, the size of the processor became
much smaller
A microprocessor is a multi-purpose, programmable, integrated
logic device that reads binary instructions from a storage device
called memory, accepts binary data as input and processes the data
according to those instructions and provides result as an output.
2 September 2023

Contd…
Differences between microcomputer, microprocessor and
microcontroller
Microcomputer– a computer with a microprocessor as its CPU.
Includes memory, I/O
Microprocessor– silicon chip which includes ALU, register circuits
and control circuits
Microcontroller– silicon chip which includes microprocessor,
memory and I/O in a single package.
2 September 2023

Organization of Microcomputers
Microcomputer – a computer with a microchip(microprocessor) as
its CPU.
It Includes memory and I/O
It combines three basic components
Microprocessor, memory and I/O
Block diagram of Micro-computers
2 September 2023

Contd…
Expanded diagram of Microcomputers
2 September 2023

Contd…
A typical programmable machine has basic three components :
1. Processor,
2. Memory
3. I/O (input/output) :Hardware
A set of instructions written for the processor to perform a task is
called program
A group of programs is called software.
2 September 2023

Microprocessor
 a multi-purpose, programmable device
 Reads binary instructions from a storage device called
memory
 Processes data according to the instructions
 Provides results as output
2 September 2023

Contd…
 Microprocessor applications are in two classified primarily
categories :
Reprogrammable Systems : Micro computers
Embedded Systems : photocopying machine, Digital camera
Operates in binary digits 0 and 1, bits.
Electrical voltages in the machine, generally 0 - low
Voltage level and 1 level, - high voltage level
A group of bits, word
Word length of 8 bits - byte
Word length of 4 bits - Nibble
A command in binary to accomplish a task- instructions.
Instructions
entered through input devices
can be stored in a storage device called memory
2 September 2023

Contd…
Microprocessor as an integral part of computer
2 September 2023

Contd…
Microprocessor based programmable controllers
A controller or microprocessor-based controller can be
subdivided into two categories :
1. Programmable Logic Controllers
2. Microcontroller
2 September 2023

Contd…
Micro controller
A microprocessor-based system
Implements the functions of a computer and a controller on a
single chip
Typically programmed for one application
Dedicated to a specific control function
Automobiles, aircraft, medical electronics and home
appliances
It is small and can be embedded in an electromechanical
system without taking up much space
Functions are completely designed into the chip.
Very little user programmable memory
Motorola 68HC11, Zilog Z8 and Intel MCS51 and 96 series.
2 September 2023

Contd…
Functions
On/Off
Timing
Control
 Sequencing
Data Handling
Counting
Arithmetic
2 September 2023

Contd…
special form of
microprocessor-based controller that uses a programmable
memory to store instructions and to implement functions such as
logic, sequencing, timing, counting and arithmetic in order to
control machine and process.
The main advantage of PLC is that:
It is flexible
Cost effective
Can be used for any control system complexity
Easer to troubleshoot
Programmable Logic Controller
A programmable logic controller is a
2 September 2023

Contd…
Advantages
PLC Saves
Material cost
Installation cost
Troubleshooting
Labor cost
By Reduced wiring & associated
errors
Less space
No moving parts - rugged
Possibility of reprogramming
Value added benefits
 Reliability
 Flexibility
Advanced Function
Communication
Speed
Diagnostics
2 September 2023

Contd…
Disadvantages
Too much work required in connecting wires.
Difficulty with changes or replacements.
Difficulty in finding errors; requiring skillful work force.
2 September 2023

Contd…
Basic Components of a PLC System
Network Interface
Most PLCs have the ability to communicate with other devices.
The PLC will communicate to the other devices through a
network interface.
Various Brands in PLC
Allen Bradley
Siemens
Modicon
Mitshubishi
GE Fanuc
Omron
USA
Germany
France
Japan
USA
Japan
2 September 2023

Contd…
PLC’s Come in a Variety of Sizes...
Pico
 Typically less than 20 I/O
Micro
Typically less than 32 I/O
Small
 Typically less than 128 I/O
Medium
Typically less than 1024 I/O
Large
Typically greater than 1024 I/O
2 September 2023

Contd…
Variety of Shapes/Configurations
Packaged
 MicroLogix 1000,1200 and 1500
Packaged with expansion
 MicroLogix 1200 and 1500
Modular (rack less)
 MicroLogix 1200 and 1500
Modular (rack based)
 SLC 500 and PLC5
Distributed
SLC 500 and PLC5
2 September 2023

Contd…
Packaged PLC
Power supply, inputs, outputs and communication port are
enclosed in a single package. Input and output devices are wired
individually to the packaged controller.
Packaged PLC With Expansion
Base is identical to the standard Packaged PLC, but it also has the
ability to drive additional I/O. The most common form of
expansion is a block of I/O that uses the same base, or makes use
of different types of expansion “modules”.
2 September 2023

Contd…
Modular PLC’s
Mix N Match Components
Processors, Power Supplies and I/O are plugged into a rack
or chassis
Available in Small, Medium, and Large platforms
Flexibility results in higher costs when compared to
packaged
Modular Rack-Less PLC’s
Identical in functionality to rack based PLC’s
Typically not as robust (packaging)
Typically found on “smaller” (small and medium) sized PLC’s. Will
likely become the prevalent form of packaging in the future
2 September 2023

Contd…
One of the benefits of a PLC system is the ability to locate the I/O
modules near the field devices to minimize the amount of wiring
required.
PLC Hardware System
A PLC system has five basic components
The processor unit
Memory
The power supply unit
Input / output interface
Programming device
PLCArchitecture
The Structure of PLC is based on the same principles as those
employed in computer architecture.
2 September 2023

Input –output devices
Input devices are connected to the terminal strip under the bottom
cover of the PLC.
Electrical contacts, pushbuttons and switches as input devices
2 September 2023

Input –output devices
Output devices, such relays and light, are connected to the
terminal strip under the top cover of the PLC.
Actuators, relays, indicator lamps, solenoids etc are out put
devices
2 September 2023

Contd…
Electrical Contacts
Electrical contacts are of three types
 Normally open(NO),
 Normally closed(NC), and
 Changeover (CO)
2 September 2023

Contd…
Actuators and Switches
 The device, which changes the state of a contact is called an
actuator
 The combination of an actuator and one or more contacts is
called a switch
 Push button switch
 A key selector
 Foot switches
 Roller lever switches and plunger operated switches : limit
switches
2 September 2023

Contact symbol
2 September 2023

Bit Logic
Bit Logic
POSITIVE & NEGATIVE Transition
The Positive Transition (EU) contact allows power to flow for
one scan for each off-to-on transition.
The Negative Transition (ED) contact allows power to flow for
one scan for each on-to-off transition.
2 September 2023

Contd…
Bit Logic
SET & RESET
The Set (S) and Reset (R) instructions set (turn on) or reset (turn
off) the specified number of points (N), starting at the specified
address (Bit). You can set or reset from 1 to 255 points.
If the Reset instruction specifies either a timer bit (T) or counter
bit (C), the instruction resets the timer or counter bit and clears
the current value of the timer or counter.
2 September 2023

Timers
Timers are devices that count increments of time. They are used
with traffic lights, for example, to control the length of time
between signal changes.
2 September 2023

Contd…
Timers
2 September 2023

Contd…
Timer
s
2 September 2023

Counters
Counters
2 September 2023

Contd…
Counters
2 September 2023

Chapter Six
CLOSED LOOP
CONTROLLERS
CHAPTER 6
2 September 2023

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