Lecture 1
Introduction
Text Book:
ELEC 483-001
Sensors and Actuators SENSORS AND ACTUATORS: Control System Instrumentation, C. W. d
e Silva, CRC Press, ISBN: 1420044834, 2007
Kalyana C. Veluvolu References:
#IT1-817 MECHATRONICS - An integrated approach, C. W. de Silva, Taylor & Fra
Tel: 053-950-7232 ncis, CRC Press, Boca Raton, FL, 2005
E-mail: veluvolu@ee.knu.ac.kr
Website: http://ncbs.knu.ac.kr Introduction to Mechatronics and Measurement Systems, Histand, M. B.
& Alciatore, D. G., McGraw-Hill, 2003
School of Electronics Engineering
Kyungpook National University
LECTURE NOTES DOWNLOAD
http://ncbs.knu.ac.kr
1
Lecture 1 Week Topic Lecture 1
Introduction Introduction
1 Introduction
Grading Policy 2 Performance specification and analysis
3 Sensors and transducers
4 Analog sensors for motion
5 Effort sensors
6 Torque sensors
Assignments constitute 20% of the grading.
7 Tactile sensing
Syllabus 8 Midterm exam
A total 3-4 Assignments will be given and students are
9 Digital transducers
required to submit it by the due date.
10 Actuators
Copying of the solutions from solution manuals and from 11 Continuous drive actuators
friends will be penalized. 12 Continuous drive actuators
13 Hydraulic actuators
LECTURE NOTES DOWNLOAD
14 Component interconnection and signal conditioning
http://ncbs.knu.ac.kr 15 Final exam
4
3
How Important are Sensors in Today’s World? Reasons for Crash of AF 447
1. Faulty Speed Sensor (Due to Icing)
2. Wrong Control Action from the Pilot
Damn it, we’re going to crash, this can’t be happening’
: Last words from Pilot
(10 Seconds before the actual crash)
5 6
Autonomous Cars (Driverless Cars) Control, Instrumentation, and Design Lecture 1
Introduction
Disturbance
Power Power Power excitation
Control Power
signal (for active sensors)
Reference Controller
Signal
(Digital or Actuator
Conditioning
Analog)
Drive Response
excitation
Sensor/
Transducer
Mechanical system
(Plant, Process)
Signal
Feedback signal Conditioning
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Power
7
Actuators Lecture 1 Sensors and Actuators used in some common engineering applications Lecture 1
Introduction Introduction
Actuators are needed to perform the control actions as well as drive the plant directly.
Two types: Process Typical sensors Typical actuators
Direct type: Motors of a robot arm like Aircraft Displacement, speed, acceleration, DC motors, stepper motors, relays,
Indirect: Opening a valve of a hydraulic system which does the actual work elevation, heading, force, pressure, valve actuators, pumps, heat source
temperature, fluid flow, voltage, cur- jet engines
Sensors rent, global positioning system (GPS)
Sensor is an element in mechatronic or measurement system that detects the magnitude Automobile Displacement, speed, force, pressure, DC motors, stepper motors, valve
of a physical parameter and changes it into a signal that can be processed by the system. temperature, fluid flow, fluid level, actuators, pumps, heat sources
voltage, current
Often the active element of a sensor is referred as a transducer
Home heating Temperature, pressure, fluid flow Motors, pumps, heat sources
system
Milling machine Displacement, speed, force, acoustics DC motors, AC motors
temperature, voltage, current
Robot Optical image, displacement, speed, DC motors, stepper motors, AC
force, torque, voltage, current motors, hydraulic actuators
Wood drying Temperature, relative humidity, AC motors, DC motors, pumps,
kiln moisture content, air flow heat sources
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Sensors and Actuators employed in Automobiles Lecture 1 Sensors and Actuators employed in Aircrafts Lecture 1
Introduction Introduction
Different kinds of Sensors Engine actuators
Air control valve Digital linear actuator
Brushless DC drives
Pumps – Electrical water and Transmission oil pumps Electronic Throttle Control (ETC) actuator
11 12
Sensors and Actuators employed in Robotics Lecture 1
Introduction Sensors/Actuators Trends
Lecture 1
Introduction
Bioloid, the most advanced robot, which is upgraded with powerful humanoid
functions and software
Bioloid is equipped with servo actuator, gyro sensor, IR sensor, and DMS sensor
Worldwide sales of sensors/actuators are forecast to grow 14% to a high
of $9.9 billion in 2014, followed by a 16% increase in 2015 to $11.4
billion
Between 2013 and 2018, the sensors/actuators market is projected to rise
by a compound annual growth rate (CAGR) of 11.7% to reach $15.1
billion
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Lecture 1 Lecture 1
Control System Architecture Introduction Open-loop Control Introduction
Reference Signal Control Output Controlled
Actuator Plant
Conditioning H/W variable
Reference Signal (Output)
Controller Actuator Plant
Conditioning
Signal Analog sensor/
Feedback signal Conditioning transducer
Plant is the system or process that we are interested in controlling No measurement of the response of the system to make it behave in
the desirable manner
Control means to make the system respond in a desired manner. To
accomplish this, we must have access to the drive system or actuator of
the plant Plant has to be stable and completely and accurately known
In feedback control systems, the control loop has to be closed
The output measurements are made primarily using analog devices, Inputs to the plants has to be precisely generated
typically consisting of sensor-transducer units
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Lecture 1
Example: Control the speed of a rotating disk Lecture 1
Feedback (Closed-loop Control) Introduction Introduction
Open-loop control
Reference Output A DC motor is selected as an actuator to provide the disk rotation
Controller Plant
DC amplifier provides required power to the motor
Measurement
Feedback signal From sensors
Measure the response and compare it with a reference to minimize the
error Open-loop (without feedback) control of the speed of a rotating disk
On-off control (bang-bang)
Proportional (P) control
Proportional control with integral (I) and derivative (D) action – PID
control
Block diagram model
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Example: Control the speed of a rotating disk Lecture 1
Digital Control Lecture 1
Introduction Introduction
Closed-loop control Real-time
clock
Reference input Digital
Drive Outputs
control DAC Plant
system
ADC processor
Address
Analog
Analog Signal
sensors/
Closed-loop (with feedback) control of the speed of a rotating disk multiplexing conditioning
transducers
Address
Digital
Digital
sensors/
multiplexer
transducers
In digital control, digital computer serves as the controller
Computers have to be fast and dedicated machines for real-time operations
Block diagram model 19 20
Major advantages of digital control Lecture 1
Feedforward Control Lecture 1
Introduction Introduction
Less susceptible to noise or parameter variation in instrumentation Unknown
Measurement Input
Very high accuracy and speed
for
Handles repetitive tasks extremely well through programming feedforward
Complex control laws and signal conditioning methods can be Output
Reference
programmed Controller Plant
Large amount of data can be stored using compact, high-density data-
storage methods
Data can be stored or maintained for very long periods of time
Measurement
Digital control has easy and fast data retrieval capabilities
Feedback signal From sensors
Digital control is cost-effective
Digital processing uses low operational voltages(e.g., 0 to 12 V DC)
In addition to feedback control, feedforward control is used to reduce
the effects of a disturbance input that enters the plant
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The disturbance input is measured and fed into the controller
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Lecture 1 Lecture 1
Distributed Control Introduction Hierarchical Control Introduction
Geographic distribution
For complex processes with a large number of input or output variables,
centralized control is difficult to implement Level 3 Supervisory
control
computer
Form of distributed control is appropriate in large systems such as
Process plant 1 2 … p
manufacturing work cells, factories, multi-agent robotic applications
Functional
Fieldbus distribution
Level 2 Control-setting
(Foundation fieldbus, industrial Ethernet, etc. computer
Internet
(TCP/IP,UDP) Local control 1 2 … l
system Set points (reference inputs)
PD1 PDr DDC Control Plant Outputs
PLC DCS Level 1
(with direct I/O) (with direct I/O) computer actuator subsystem
PD = Process device Feedback
PLC = Programmable logic controller signals Sensors/
DCE = Distributed control system (Supervisory controller) transducers
23 24
Lecture 1 Instrumentation and Design Lecture 1
Hierarchical Control Introduction Introduction
Identification of hardware components w.r.t their functions, operation, interfacing,
tuning of the components, etc., in short, instrumenting a control system
Identification of design parameters, modelling of various components, and
analysis are often useful in the design process
Modelling is important in analyzing, designing, and evaluation of a control
system
Digital control Signal Process
computer conditioning Sensor
User
commands Response
Actuator
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Signal conditioning/filtering 26
Lecture 1
Components Introduction
Controllers: P, PI, PD, PID, Digital
Actuating devices: Stepper motors, AC motors, DC motors, solenoids,
valves, and relays
Sensors: Potentiometers, differential transformers, resolvers, synchros,
gyros, strain gauges, tachometers, piezoelectric devices, fluid flow
sensors, pressure gauges, thermocouples, thermistors, resistance
temperature detectors
Signal conditioning devices: Charge amps, power amps, filters (low-
pass., high-pass, band-pass, notch)
Power supplies
Protection devices
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Design considerations
Lecture 1
Introduction
Comparison of some common control actions Lecture 1
Introduction
Performance
Quality Control Control Advantages Disadvantages
Cost Action Law
Speed On-Off 1 Simple Continuous chatter
2 Inexpensive Mechanical problems
Ease of operation Poor accuracy
PID control Proportional Simple Offset error (Steady state error)
Fast response Poor stability
1
Integral 1 Eliminates offset Low bandwidth (slow response)
Filters out noise Instability problems
= error signal (controller input) Rate High bandwidth Insensitive to DC error
= control/actuating signal (controller output or plant input) (Derivative) (Fast response) Allows high-frequency noise
Improves stability Amplifies noise
= proportional gain Difficult analog implementation
= derivative time constant
= integral time constant 29 30
Programmable logic controllers (PLC) Lecture 1
Introduction Example: Operation of a turbine blade manufacture
Lecture 1
Introduction
PLC is a digital-computer-like system
- sequence a complex task: discrete operations, several devices Move the cylindrical steel billets into
furnace
PLCs are rugged computers typically used in factories and process
plants Heat the billets
Computation and control tasks When a billet is properly heated move it
to the forging machine
- PID control: continuous-state control, process variables continuously
monitored and made to stay close to desired values Forge the billet into shape
- Discrete-state control Perform surface finishing operations to
get the required aero foil shape
* sequence of states (Steps)
When the surface finish is satisfactory,
* in steps there may be continuous-state control machine the blade root
PLCs are particularly intended for accomplishing discrete-state control
31 32
Programmable Logic Controller Hardware Lecture 1 Lecture 1
Introduction Performance characteristics Introduction
Stability
- A stable system will respond in a reasonable manner to an applied input
- Asymptotic stability: Response decays back to initial steady state for initial
condition excitation
- Bounded input bounded output (BIBO) stability: The response to bounded
input should be bounded
Speed of response (bandwidth): System should react quickly to a control input
Sensitivity and robustness
- Low sensitivity to noise, external disturbances, modeling errors, and
parameter variations
- High sensitivity to control inputs
Accuracy
- Low error, tracking error and steady state error
Cross sensitivity (dynamic coupling)
- Reduced coupling among system variables
33 34
Summary Lecture 1
Introduction
Actuators are needed to perform the control action s as well as to drive the
plant directly
Sensors and transducers are necessary to measure output signals (process
responses) and to measure input signals for feedforward control
Open-loop (OL) and Closed-loop (CL) systems
OL control system uses a controller and actuator to obtain desired response
Input Process Output
CL control systems use an additional measure of the actual output for
feedback
Desired Actual
Output Controller Process
Output
Feedback (measurement) 35
