Mechatronics - New York University

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MechatronicsDr. Kevin CraigAssociate Chair for Graduate Studies &Associate Professor of Mechanical EngineeringDepartment of Mechanical Engineering, Aeronautical Engineering, & MechanicsRensselaer Polytechnic InstituteTroy, NY 12180Office: JEC 2046 Phone: 518-276-6671E-Mail: craigk@rpi.edu Fax: 518-276-6025Mechatronics Laboratory: JEC 1022 Phone: 518-276-8978MechatronicsIntroductionK. Craig1

What is Mechatronics?Mechatronics is thesynergisticcombination ofmechanicalengineering,electronics, controlsengineering, andcomputers, allintegrated through thedesign process.MechatronicsIntroductionK. Craig2

Electro-Mechanical DesignsType 1:Electronics,Computers, &Controls AddAdditionalOperationsType 2:Electronics,Computers, &Controls ImpartAdditionalFunctionsType 3:Electronics,Computers, &ControlsProvide SystemSynergyType 3Designs icsIntroductionK. Craig3

“Over the Wall” gnDesignDesignManufacture Manufacture Manufacture ManufactureMechatronicsIntroductionK. Craig4

Concurrent gnDesignDesignDesign Manufacture Manufacture Manufacture ManufactureMechatronicsIntroductionK. Craig5

ign ManufactureMechatronicsIntroductionK. Craig6

The Design ChallengeThe cost-effective incorporation ofelectronics, computers, and controlelements in mechanical systemsrequires a new approach to design.The modern engineer must drawon the synergy ofMechatronics.MechatronicsIntroductionK. Craig7

Difficulties in Mechatronic Design MechatronicsIntroductionRequires System PerspectiveSystem Interactions Are ImportantRequires System ModelingControl Systems Go UnstableK. Craig8

Balance: The Key to dwareImplementationThe Mechatronic System Design ProcessComputer Simulation Without Experimental VerificationIs At Best Questionable, And At Worst Useless!MechatronicsIntroductionK. Craig9

Balance in Mechatronics is the Key!The essential characteristic of a mechatronics engineer andthe key to success in mechatronics is a balance between thefollowing sets of skills: modeling (physical and mathematical), analysis (closedform and numerical simulation), and control design(analog and digital) of dynamic physical systems experimental validation of models and analysis (forcomputer simulation without experimental verification is atbest questionable, and at worst useless!) andunderstanding the key issues in hardware implementationof designsMechatronicsIntroductionK. Craig10

Dynamic System nalysisMechatronicsIntroductionK. Craig11

Measurements,Calculations,Manufacturer's SpecificationsModelParameterWhich Parameters to Identify?What Tests to rimentalAnalysisAssumptionsandEngineering JudgementPhysical LawsModel orAugmentEquation Solution:Analyticaland NumericalSolutionModel Adequate,Performance InadequateModel Adequate,Performance AdequateCompleteDynamic System InvestigationMechatronicsIntroductionK. Craig12

Mechatronics is NOTConcurrent EngineeringCONCURRENT ENGINEERINGBridges Design and Manufacturing.Electrical, Mechanical, Control and Computer EngineersOperate in Separate Environments.(vertical integration)MECHATRONICSIntegration of Electrical, Mechanical, Control, and ComputerEngineering Knowledgein Both Design and Manufacturing.(horizontal & vertical integration)MechatronicsIntroductionK. Craig13

Mechatronics is NOTElectromechanicsELECTROMECHANICSDesign of prime movers: a.c. motors, d.c. motors, solenoids.Design of generators. Control of motors: commutationof d.c. motors, startup of a.c. motors.MECHATRONICSThe synergistic combination of actuators, sensors, controlsystems, and computers in the design process.MechatronicsIntroductionK. Craig14

Mechatronics is MORE than justControl SystemsMechatronics draws heavily on the concepts of controlsystems only because they provide a coherentframework for system analysis.Controls are an integral component to any mechatronicdesign and not an afterthought add-on.However, open-loop and feedforward control structuresare as valid as feedback ones for design solutions.MechatronicsIntroductionK. Craig15

Benefits of MechatronicsMechatronics is spawning a new breed ofintelligent components and systems that combinean optimum blend of all available technologies. MechatronicsIntroductionShorter Development CyclesLower CostsIncreased QualityIncreased ReliabilityIncreased PerformanceIncreased Benefits to CustomersK. Craig16

The Realm of Mechatronics MechatronicsIntroductionHigh SpeedHigh PrecisionHigh EfficiencyHighly RobustMicro-MiniatureK. Craig17

Mechatronic Design Concepts Direct Drive MechanismsSimple MechanicsSystem ComplexityAccuracy and Speed from ControlsEfficiency and Reliability from ElectronicsFunctionality from MicrocomputersThink System !MechatronicsIntroductionK. Craig18

Mechatronics Engineer Leader in the initiation and integration of design Interdisciplinary knowledge of varioustechniques Ability to master the entire design process fromconcept to manufacturing Ability to use the knowledge resources of otherpeople and the particular blend of technologieswhich provide the most optimal design solutionMechatronicsIntroductionK. Craig19

Mechatronic Areas of Study Mechatronic system design principlesModeling, analysis, and control (continuous and discrete)of dynamic physical systemsAnalog and digital control electronicsControl sensors and actuatorsInterfacing sensors, actuators, and microcontrollersReal-time programming for controlAdvanced topics, e.g.,- fuzzy logic control- smart materials as sensors and actuators- magnetic bearingsMechatronicsIntroductionK. Craig20

Challenge to Industry Control Design and Implementation is still the domain ofthe specialist. Controls and Electronics are still viewed as afterthoughtadd-ons. Electronics and Computers are considered costly additionsto mechanical designs. Few engineers perform any kind of modeling. Mathematics is a subject not viewed as enhancing one’sengineering skills but as an obstacle to avoid. Few engineers can balance the modeling\analysis andhardware implementation essential for Mechatronics.MechatronicsIntroductionK. Craig21

Industry’s Choices Train the engineers you have in themechatronics approach to design. Give them the tools to be successful: Knowledge: modeling, analysis, controls Hardware: sensors, actuators, instrumentation, real-timecontrol, microcontrollers Software for Simulation and Control Design, e.g.,Matlab / Simulink, Electronics Workbench Give them the time to use these tools!MechatronicsIntroductionK. Craig22

ORHave this happen to yourengineers!MechatronicsIntroductionK. Craig23

Industry’s Bottom LineTrain your engineers in aMechatronics approach to design.Give them the tools and the time todesign with synergy andintegration.MechatronicsIntroductionK. Craig24

Mechatronics at RPIRPI MechatronicsCourses:Graduate & Undergraduate100 students / yearPortal to Industry:Professional EngineersMentoringProfessors and Studentsat RPIIntroduction toEngineering DesignSophomore Course1000 students / yearRPIMechatronicsTeachingLaboratorySchool of EngineeringCapstone Design Coursesand Student Projects500 students / yearMath, Science, EngineeringIntegrationAcross the RPI CurriculumNSF Project LINKSPDI ProgramK-12 Student & TeacherPrograms inMechatronicsRPI Center for PreCollege InitiativesRSVPDistance Learning:High SchoolsProfessionalsPreparation and Distribution of Educational Materials:Tutorials for Undergrads, HS Students, ProfessionalsbyVideotapes, CD’s, Web Sites, PublicationsMechatronicsIntroductionK. Craig25

Mechatronics Demonstrations MechatronicsIntroductionSpring-Pendulum Dynamic SystemInverted-Pendulum Dynamic System:Rotary and Arm-DrivenTwo-Mass, Three-Spring Dynamic SystemElectrodynamic Vibration ExciterHigh-Speed, Micron-Level Positioning Systemwith Variable Coulomb FrictionBall-on-Plate Balancing SystemHydraulically-Balanced Beam SystemBall-on-Beam Balancing SystemDrive-Train Friction/Backlash/Compliance TestbedK. Craig26

Spring-Pendulum Dynamic Systeml rkθMechatronicsIntroductionmK. Craig27

Mathematical Modeling and mr&& m ( l r ) θ& 2 kr F mg cos(θ) 0tAnalysis of Spring(l r)&&θ 2r&θ& gsin(θ) 0Pendulum etheta accIntegratetheta velgravity (m/s 2)cos(u)cos2GainProductSpring PendulumDynamic SystemProductu 2thetatheta positionsquareProductrr positionSum1/s1/sIntegrater accIntegrater vel95.215.710/1.815Ft 5.71 Nm 1.815 kgMechatronicsIntroductionk/mk 172.8 N/mm 1.815 kgtClocku (-1)0.333spring lengthunstretched(meters)timeSum2inverseK. Craig28

Dynamic Response of Spring-PendulumSystemSimulation Results: Initial Conditions theta 0.021 rad, r 0.115 m0.25angular and radial position (rad or tronicsIntroduction0102030time (sec)405060K. Craig29

Inverted-PendulumDynamic System:Rotary and Arm-Driven Brushed DC Motor Two Optical Encoders (2000cpr) PWM Servo-Amplifier Power Supply Pendulum Balancing Control Pendulum Swing-Up Control Classical, State-Space, andFuzzy Logic Control Converts between Rotary andArm-Driven Systems dSpace Real-Time ControlImplementationMechatronicsIntroductionK. Craig30

Multi-Mass, Multi-Spring Dynamic System MechatronicsIntroductionBrushed DC Motor with TachometerOptical Encoder with 2000 cprTwo Infrared Position SensorsFree and Forced VibrationsSystem Behavior below, at, and above resonanceDynamic Vibration AbsorberPhysical Significance of Transfer Function Poles and ZerosColocated and Non-colocated ControldSpace Real-Time Control ImplementationK. Craig31

44.5N Electrodynamic Vibration ExciterMechatronicsIntroductionK. Craig32

Physical Model of Vibration ShakerMechatronicsIntroductionK. Craig33

High-Speed, Micron-Level Positioning Systemwith Variable Coulomb Friction Actuators: Brushed DC Motor Brushless DC Motor Stepper Motor withmicrostepping 80,000 and 144,000 cprOptical Encoders Coulomb Friction Device Variable Inertia Direct or Belt Drive MatLab Modeling andControl DesignEnvironment dSpace Real-Time ControlImplementationMechatronicsIntroductionK. Craig34

Ball-on-Plate Balancing System Two Brushed DC Motors Two Optical Encoders(4000 cpr) Touch-screen ResistiveBall-Position Sensor Two PWM ServoAmplifiers Two Power Supplies Disturbance Rejection Ball Position CommandTracking, e.g., line, circle,figure eight dSpace Real-Time ControlImplementationMechatronicsIntroductionK. Craig35

Hydraulically-BalancedBeam SystemMechatronicsIntroduction System Converts betweenOpen-Loop Stable andOpen-Loop UnstableConfigurations Two Gear Pumps Two Pressure Sensors atTank Bases to DetermineLiquid Height Potentiometer for BeamAngle Two PWM ServoAmplifiers Two Power Supplies Disturbance Rejection Position and VelocityCommand Tracking Linear and NonlinearControl Techniques dSpace Real-Time ControlImplementationK. Craig36

Ball-on-BeamBalancing SystemMechatronicsIntroduction Brushed DC Motor Beam Sensors:Optical Encoder,Tachometer,Potentiometer Ball Sensors:Ultrasonic,Potentiometer,Phototransistor PWM ServoAmplifier Power Supply DisturbanceRejection Ball PositionCommand Tracking dSpace Real-TimeControlImplementationK. Craig37

bed to Study the Effects ofGear Backlash, Drive-ShaftCompliance, Coulomb Friction& Variable Inertia on AccuratePositioningMechatronicsIntroductionK. Craig38

Mechatronic System Case Studies Thermal System Closed-Loop TemperatureComputer Control Pneumatic System Closed-Loop PositionComputer Control Stepper Motor Open-Loop and Closed-LoopComputer Position Control DC Motor Closed-Loop Speed Control Analog Control Digital Control with Embedded Microcontroller Magnetic Levitation System MR Fluid Rotary Damper SystemMechatronicsIntroductionK. Craig39

Two-Person MechatronicsLaboratory Station Pentium Computerwith MATLAB,ElectronicsWorkbench, andWorking Model Function Generator Digital Oscilloscope Multimeter Powered Protoboard Microcontroller Assorted analog /digital sensors,actuators andcomponentsMechatronicsIntroductionK. Craig40

Blue Earth Micro 485 SpecificationsBlue Earth Micro 485 tel 8051 running at 12 MHzDigital I/O27 Bi-directional TTL compatible pinsAnalog Inputs4 12-bit 0-5 volt A/D converter channelsSerial CommunicationRS-422, RS-232RAM128K, battery-backed for retention after power downROM32K, contains on-board Basic and MonitorMechatronicsIntroductionK. Craig41

Thermal System Closed-LoopTemperature Control aluminum plate thin-film resistive heater ceramic insulation conduction and convectionheat transfer AD590 temperature sensor microcontroller on-off closed-loop controlwith relay support analog electronicsMechatronicsIntroductionK. Craig42

Pneumatic System Closed-Loop PositionControl 3/4” bore, double-acting, nonrotating air cylinder linear potentiometer to measuremass position 30 psig air supply two flow-control valves two 1/8”ported, 3-way, springreturn, two-positionsolenoid valves Darlington switches toenergize solenoids microcontroller on-off, modified on-off, PWMclosed-loop controlMechatronicsIntroductionK. Craig43

Schematic of Pneumatic ServomechanismPneumatic Positioning Closed-Loop Control SystemPowerSupplySupply Air30 psigValve AValve BManual Flow Control ValvesDarlingtonSwitches1/8 Inch Ported, 3-Way, Spring-Return,Two-Position, Solenoid ValvesMicrocontrollerwith 12-BitA/D ConverterPiston ShaftAChamber 1PistonBMassChamber 2Actuator3/4 Inch Bore, Double-Acting,Non-Rotating Air Cylinder5 VoltsLinear Potentiometer4-Inch StrokeMechatronicsIntroductionK. Craig44

Stepper MotorOpen-Loop and Closed-Loop Control stepper motor optical encoder microcontroller electronics to interface themicrocontroller to themotor and encoder full-step and half-stepoperation control via a Quad-DarlingtonIC control via a step-motor-driverIC programming in Basic or CMechatronicsIntroductionK. Craig45

Stepper Motor SystemDesign:Ink-Jet PrinterApplicationStepper Motor Open-Loopand Closed-Loop ControlMechatronicsIntroductionK. Craig46

DC Motor Closed-Loop Speed Control Permanent-magnet brushedDC motor integral analog tachometer aluminum disk load inertia PWM power amplifier 24-volt, 4-amp power supply analog control design andimplementation:lead, lag, lead-lagMechatronicsIntroductionK. Craig47

Microcontrol Motor-Speed-Control Testbed Two embedded microcontrollersfrom MicroChip Inc. configuredfor: 3 channel 8-bit analog /digital (A/D) acquisition , 10-bitpulse-width-modulated (PWM)drive, serial communication toPC, general purpose digital I/O High power H-bridge for outputstage of pulse-width-modulated(PWM) driver (for d.c. motors) Hex keypad for data entry Liquid crystal display (LCD)for data display Analog electronics (op amps) formeasuring tachometer and inputreference signalMechatronicsIntroductionK. Craig48

Magnetic Levitation System Magnetically-levitated 1/2”diameter steel ball electromagnet actuator: 1/4”steel screw with3000 turns of 26gauge wire gap sensor: infra-red diodeemitter andphototransistordetector TIP-31, NPN, bipolar transistoras a current amplifier 15 volt, 5 volt power supply analog lead controller designand implementationMechatronicsIntroductionK. Craig49

Schematic OfMagnetic Levitation SystemElectromagnetPhototransistorIR LEDControllers& PowerAmplifierObjectDevice SchematicMechatronicsIntroductionK. Craig50

Mechanical System Digital Speed Controlusing DC Motor with MR Fluid Brake MR Fluid RotaryDamper Brushed DC Motorwith Gearbox Motor Tachometer Shaft Potentiometer Current Controller PWM Power Amplifier 24-Volt, 4-Amp PowerSupply AC/DC Adapter Pulley / Arm Attachedto MR FluidBrake Microcontroller withD/A ConverterMechatronicsIntroductionK. Craig51

All these systems areindustrially relevant and requirea complete dynamic systeminvestigation with a balancebetween modeling / analysis andhardware implementation.Only a Mechatronicsengineer can accomplishthis!MechatronicsIntroductionK. Craig52

MechatronicsExercise Examples Analog Electronics: Time Response,Frequency Response, Loading Effects Dynamic System Modeling and Analysis:Space Station Solar Alpha Rotary Joint Modeling, Analysis, and Control of anElectrohydraulic tionK. Craig53

Analog Electronics:RC Low-Pass FilterTime Response &Frequency ResponseTime Response10.90.8Vout1 Vin RCs 1Amplitude0.7Resistor 15 KΩ0.60.50.40.30.2VinCapacitor 0.01 µFVout0.10012345Time (sec)678x 10Time Constant τ RCMechatronicsIntroductionK. Craig54-4

Frequency Response00-20Phase (degrees)Gain dB-5-10-15-40-60-80-20-2521031010Frequency (rad/sec)4105-100210341010Frequency (rad/sec)10Bandwidth 1/τMechatronicsIntroductionK. Craig555

Analog Electronics:Loading EffectsLMV OP LMRCs 1N i Q N CsResistor 15 KΩininVinCapacitor 0.01 µFVoutOPLM OP 1 Q N i Q R VoutoutVout11 VinRCs 1 τs 1Z out Z in Vouti outVini in Vin 0 i out 0RRCs 1RCs 1Cswhen i out 0Output ImpedanceInput ImpedanceRC Low-Pass FilterMechatronicsIntroductionK. Craig56

FGHIJ FG 1 IJK H RCs 1KVout1 G (s)1 unloaded G(s)2 unloaded VinRCs 1Vout G (s)1 loaded G (s) 2 unloadedVinResistor 15 K ΩVinCapacitor 0.01 µFResistor 15 KΩCapacitor 0.01 µFVoutFF 1 IJ GG 1 GH RCs 1K G 1 ZH Zout 1 in 2IJJ FG 1 IJJK H RCs 1K1bRCs 1g2 RCsOnly if Zout-1 Zin-2 for the frequency rangeof interest will loading effects be negligible.2 RC Low-Pass Filters in SeriesMechatronicsIntroductionK. Craig57

Space Station Solar Alpha Rotary Joint:Physical System and Physical oaBodyrd xRLStatorVin im dMechatronicsIntroductionN:1Gear RatioK2JsaJobθ ′mB1θ obB2θ sa xTdK. Craig58

Solar Alpha Rotary JointMathematical ModelLM 0LM θ& ′ OP M 0MMθ&& PP MM 0KθMM &&θ′ PP MM N JMM&&θ PP MM JKMN&&θ PQ MM 1N 2J m K1 K 2J obK2J sa0000 B1N 2J mB1J ob10B1N 2J m B1 B2J obB2J sa0K2J ob K2J sa0OPL 00 PL θ ′ O M01 PMMθ PP MM 0P0 PM θ P M NKMM θ& ′ PP M N JPB PM&θ P M 0MJ PM P B PMN θ& PQ MM 0PNJ PQ0mobsat2m2ob2obsaOP0 P0 Pi OLP0 PM PNT QP0 P1 PJ PQ0mmdsasaK. Craig59

Frequency Response Plots: Input imGain dB0θobθ′m-200θsa-400-110100110Frequency troductionθ′m-1100101102103K. Craig60

Time Response: im cos(0.6t)0.02θ sa0.0180.016Amplitude0.0140.0120.01θ ′mθ 015Time (secs)2025K. Craig61

Electrohydraulic tionK. Craig62

Nonlinear ModelELECTROHYDRAULIC VALVE-CONTROLLED SERVOMECHANISMQclTo Workspace2inputTo Workspace6Xv CommandXv Step CommandXcQcrXv - Xc PositiveXv - Xc PositivePclQclQclXv - Xc PosXv - Xc NegQcr QcrPcrXv - Xc NegativeXv - Xc NegativeControllerTo Workspace3FlowXcTo Workspace1PclTo Workspace4Xc XcPclPcrXc dotMassXc dotXcQclQcrXc dotPclPcrPclPcrTo tionTo WorkspaceK. Craig63

Linear Mathematical ModelcC xxc C xxv ,pv ,pMechatronicsIntroductioncl ,phchhdxC ,pV0 dp cr ,p K pl p cl ,p p cr ,p A pM B dtdt C p p cr ,pcpch C p p cl ,pdxC ,pV0 dp cl ,p K pl p cl ,p p cr ,p A pM B dtdt p cr ,pdxC ,pd 2 x C ,pAp B f U ,p Mdtdt 2hK. Craig64

Linear ModelPcl lSum5 To ain2MB/Vo1/sCpGain3Gain5Gain7Sum6Aptime lTo WorkspaceClock0Sum4DisturbancefuGain8Pcr lTo Workspace2Gain9Sum8input lTo Workspace6CxQcl lTo 21/MSum1GainB1/s1/sIntegratorIntegrator1XcQcr lTo Workspace5Xc lTo Workspace3Gain1Xv Step CommandMechatronicsIntroductionELECTROHYDRAULIC VALVE-CONTROLLED SERVOMECHANISM (LINEAR)K. Craig65

Take the Laplace Transform of these linear equations andderive six useful transfer functions relating the two inputs, xvand fU, to the three outputs, pcl, pcr, and xC.LMV s M cKMM CKMMMC AMMN0BxplBplxpMechatronicsIntroduction Cph K plCx V0s M B K pl C pcCx M BAphOPPPPPPPQA psCxA psCxMs2 BsLMpMMpxNclcrCOP LMx OPPP MMxf PPQ N QvvUK. Craig66

af FGHxCs xvOne of these transfer functions is:K where2C x A pc2A 2p B C p 2K plcKs2 2ζss 2 1ωn ωnhM B 2A 2p B C p 2 K plωn IJKhMV0FG 2M M IJ K FG M M IJ CH V K H V KM M2A BcC 2 K hVB ζ BBplp02B02pppl0MechatronicsIntroductionK. Craig67

Introduction K. Craig 15 Mechatronics draws heavily on the concepts of control systems only because they provide a coherent framework for system analysis. Controls are an integral component to any mechatronic design and not an afterthought add-on. However, open-loop and feedforward contro

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