Mechatronics jumps ‘The jump instruction is an outp be jumped over. ut instruction enabling part of a ladder program to, With the jump instruction, the processor scan time can be reduced by jumping over instructions not pertinent to the machine operation. Consider a Ladder diagram with jump instruction. |_ 4) 1 Program A O Input 4 1 [cxP} Program B ‘4 UV I _-) EJP C) ~~ | Program C Figure 4.42 Jump . Program A rung is encountered with input 1 and the conditional jump relay CJP. If input 1 occurs then the program jumps to the rung with the end of jump relay coil EJP and so ’ continuous with that section of the program labeled as C, otherwise it continues with the program rungs labeled as program B. Flowchart describes Jump Instructionee eal ptt ears eemeeeersspinennsemgpeeneesegelaptnadnargapscnechegenarengemermteres deaminsciiiad 412, SELECTION OF PLO SEMOWOF PLO SE SS eee In generel, PLC are considering the size and type required for particular tasks or tssks criteria that need to be considered are, Input/Output capacity required Types of Inputs/output required Size of memory required Speed end power of CPU Rather than basic consideration, we need to consider the following aspect jepending on the requirements of the specific application, eo % + 4. System definition A technique of functional decomposition can be applied to define the whole system, with hardware and software, as it is defining the program alone. 2.Choosing the VO hardware Various types of input and output modules ‘are available, based on the type and speed of operation. A list of modules and the size of the PLC system are determined by knowing the member of any type of I/O line we need, and the number of the lines available on a given module. .UO timing consideration it is most important to determine how fast (speed of operation) the sub-system of ‘input program and output must react to changing input conditions, Normally, the Speed of operation will be the sum of the input hardware delays, plus the PLC scan time plus any output hardware delays. ‘Analog UO module Hah are many terms used to set out to select. analog modules for deseribing ice. They are as follows:Mechat tan fechatronioy Ce 4 Resolution: Define how accurately the analog-to-digital (A/D) or digitalsto. analog (D/A) converter within the module can represent an analog voltage as 4 binary number or vice versa. & Isolation: Refers to the ability of each unit/input to work at a voltage level independent of the system ground, > Voltage level: it is essential to know the maximum voltage of the input to be measured, and then the modules voltage range is selected just greater than this level. Most output modules provide 4: 10 V outputs. This can be scaled with a potential divider to the required level. * Current level (1/0 module): A 4-20 mA current loop for input is the common choice inorder to avoid all the problems of voltage level selection. A4-10A current loop output is always advantageous to use. 5. Conversion speed The choice of conversion speed basically depends on the number of readings per second we need to capture. There are two types of A/D converters. A converter which performs a conversion every 20 ms gives a good clean reading free from line frequency interference. The other one will convert in 2-20 ms for measuring transient input data. 6. Analog closed contro! Analog inputs sometimes are used as feedback to control a process by controlling relay outputs or varying an analog output. In such case, scan speed must be estimated from the program size taking into account the execution speed of the controller module. 7. Counters, encoders and positioning In order to select the PLC hardware, we need to consider (a) the speed, (b) the total numbers of pulses to be counted, (c) the positioning accuracy. : 8, Communications When we are selecting a PLC, we need to evaluate the communication facility is adequate for the application, All PLCs have some sort of built in communications facility through the programmer port, If a built-in communication facility is not | sufficient then the option of add-on ports, high-speed LAN, etc, should be considered.Programmable Logte Controller 9, Choosing the correct processor A PLC processor is selected based on capacity, functionality; program speed and size. Capacity is determined by the capability of the processor to work with a number of each type of module, Functionality of PLC is the capability to be programmed to petform the logical operations required for the control of plant and sequences. The program scan speed is dependent upon the speed of operation of the PLC and the length of the program. The maximum speed of PLC that any input is read of any output is switched is equal to the program scan time. The size of program is dependent upon the complexity of the control program and the skill and style of the programmer. 40. Selecting suppliers The choice of supplier for a PLC is based on the following 4 4 Functionality and features “ Customer support “Customer acceptability “User knowledge % Cost5.8.1. CASE STUDY 1: PICK AND PLACE ROBOT The basic form of a pick and place robot is shown in Figure 5.28. The robot has three axes about which motion can occur. The following movements are required for this robot. 1. Clockwise and anticlockwise rotation of the robot unit on its base. 2. Linear movement of the arm horizontally i.e., extension or contraction of arm. 3. Up and down movement of the arm and 4, Open and close movement of the gripper. The foresaid movements can be obtained by pneumatic cylinders which are operated by solenoid actuated 4/3 way directional-control-valves (DCVs) with limit switches. Limit switches are used to indicate when a motion is completed.Actuators and Mechatronic System Design Ea Figure 5.29 Gripper mechanism of a robot The clockwise rotation of the robot unit on its base can be obtained from a piston and cylinder arrangement during pistons forward movement. Similarly, counter clockwise rotation can be obtained during backward movement of the piston in cylinder. Linear movement of the arm can result during forward and backward movement of the piston in a cylinder. The upward movement of the arm can result from forward | Movement of the piston in a cylinder. whereas downward movement from its _5.50 Mechatronics retardation. The griper can also be operated in a similar way as explained above ie, gripper is opened during forward movement of the piston and closed during backward movement of the piston in the cylinder. Figure 5.29 shows a mechanism used for this purpose. Double acting pneumatic cylinder yun Limit switches ~ q oO a BY, = Trac t=—1 Ippo optoisolatore-] 4 $ ar PBO +H Base schail se actuator [iseew7]POO Pet Ph q >——|PC1 [Eel OT PS a(R me 5 Ps * Limit = | Cymer PCs = pas switches = Poa @ a = | pime a | PCS PBS) ped PBS LE Sem] CS am ‘Arm extend/contract LL. Sip doxe [PCT £ elt pe an 4/3 way DCV Umit ‘switches =" +H ‘Arm up/down ru BS g 413 way DCV Limit ‘switches ‘ VVA) A ane : al ; HH Gripper openiclose na va, Figure 5.30 Microcontroller circuit for pick and place robot: Actuators and Mechatronte System Design A microcontroller used to control the solenoid valves of various cylinders is shown in Figure 5.30. The microcontroller used of this purpose is M6BHCI1 type, A software program is used to control the robot. TRIAC optoisolator consists of LED and TRIAC. If the input of the LED is 1, the TRIAC is glowed and activated to conduct the current to the solenoid valve. Otherwise, the TRIAC will not conduct the current to the solenoid valve. When the solenoid is activated by TRIAC, the directional control valve opens its output port and it conducts the compressed air to the double acting pneumatic cylinder to extend its piston. The connecting rod and piston assembly of the pneumatic cylinder which is connected to the respective base or arm or gripper is used to obtain the required motion.Device a circuit that could be used with a domestic washing machine to switch on pump water for 100s into the machine, then switches off and switch on a heater for 50s to heat the water. The heater is then switched off and another pump is to empty the water from the machine for 100s. [A.U, Apr/May 2008; Nov/Dec2008; Apr/May 2008; Apr/May 2010] Il —start 12 - StartMechatronics 01 -—Pump1 02 — heater T1 = Timer! (100 secs) T2 — Timer2 (50 secs) 3 — Timer3 (100 secs) M1, M2, M3 ~ Memory coil n Mi 12 01 4 01 RyRy 1 FK- {m1} M2 Poik—_—__—_{r}-— 3S 54. SERVOMOTORS There are some special types of zpplication of electrical motor where the rotation Of the motor is required for just a certzin angle not continuously for a long period of ume. For these applications, some special types of motor are required with some special exrangement which makes the motor to rotate a certain angle for given dleazical input (signal), For this purpose, a servo motor is used. Sexvomotors are special electromechanical devices that operate in precise degrees of rotation. This type of motor quickly responds to positive or negative signals from a sexv0 canplifier. The important characteristics of servomotor are as follows. Fast response - High accuracy a Fast and accurate speed Very high starting torque Unattended contro] Direction control 2 Remote operation J Due to these features, they are being used in many applications such as toy car for controlling direction of motion, RC helicopters and planes, Robotics, CD / DVD layer, CNC Machines etc. vv VOW vv5.20 Mechatronics A servomotor is a simple electric motor combined with a position sensing device (e.g. a/igital decoder) and controlled for specific angular rotation with the help of servomechanism, Servomechanism is a typical closed-loop feedback control system. The position of a servo motor is decided by electrical pulse and its circuitry is placed beside the motor, Servomotors are used when an object is required to rotate at some specific angles or distance. It is just made up of simple DC, AC or brushless DC motor which runs through servo mechanism. ‘The fundamental characteristics to be sought in any servo-motors are given below. > The motor outpat torque is proportional the voltage applied to it. > The direction of the torque developed by the servomotor depends upon the instantaneous polarity of the control voltage. 5.4.1, CONSTRUCTION AND WORKING PRINCIPLE OF SERVOMOTOR A sservo system mainly consists of the following three basic components. + + > Controlled device > Output sensor > Feedback system The servomotors used in industry today are automatic closed-loop servo system where it uses the positive feedback system to control motion and final position of the shaft. Figure 5.12 indicates a block diagram of a typical closed-loop servo system. Here, the device is controlled by a feedback signal generated by comparing the output signal: and reference input signal i.e. reference input signal is compared to reference output signal and the third signal is produced by a feedback system. This third signal acts as‘input signal to control device. This signal is present as long as the feedback signal is generated or there is difference between reference input signal and reference output signal. So, the main task of servomechanism is to maintain output of a system at desired value at presence of noises. g A servo unit consists of a small DC motor, potentiometer, gear arrangement and control circuit. The controlling circuit along with the potentiometer makes the servo to'rotate according to the requirement. A small DC motor will rotate with high speed but the torque generated by its rotation will not be enough to move even a light load: ‘Therefore, a gear mechanism is used in servo units. It reduces the speed of the motor and it increases the torque. := pm od. Mechatronic System Design - 521 Exror detector inget Controlled pee Servomotor acs Feedback loop Figure 5.12 Closed-loop servo system "ft initial position of servo motor‘shaft, the position of the potentiometer knob is ‘that there is no electrical signal generated at the output port of the potehtiometer. aplificr, the difference between these two signals (one comes from potentiometer other comes from’ other source) will be processed in the feedback mechanism the potentiometer’s angular position changes, its output feedback signal will After sometimes, the position of potentiometer reaches at a position that the spot of potentiometer is same as external signal provided. At this condition, there ‘be no output signal from the amplifier to the motor input as there is no difference Example of servomotor control system For understanding servomotor control, consider an example of servomotor which Given a signal to rotate by an angle of 45° and stop and wait for further instruction. ‘The shaft of DC motor is coupled with another shaft called output shaft with the lp of a gear assernbly shovm in Figure 5.13. This gear assembly is used to step 450m the high rom of the motor’s shaft to low rpm at output shaft of the servo system. The voltage adjusting knob of a potentiometer is so arranged with the output shaft heans of another gear assembly. During rotation of the shaft, the knob also, and it creates a varying electrical potential according to the principle of aae. | 5.22 Mechatronics potentiometer. This signal i.e. electrical potential is mer aeene ‘movement of potentiometer knob along with the system shaft from 0' be Hi ; a slectrical potential or voltage is taken to the error detector feedback amp ifier along with the input reference commends i.e. input signal voltage. In practical aa Taowor Control systems, instead of using a simple potentiometer, digital or analog position sensor encoder can be used. . As the angle of rotation of the shaft increases from 0° to 45°, the voltage from potentiometer will increase. At 45°, this voltage reaches to a a which is equal to the given input command voltage to the system. As at this position of the shaft, there is no difference between signal voltage coming from the potentiometer and reference input voltage (command signal) to the system, the output voltage of the amplifier will become zero. Gear assembly for reducing shaft speed Position cog Output shaft Potentiometer DC motor 7 Amplifier t -| Electrical input DC Reference motor Feed back path input signal Error detection complier Figure 5.13 Servomotor control system As per Figure 5.13, the output electrical voltage signal of the amplifier acts ® input voltage of the DC motor. Hence, the motor will stop rotating after the shaft | rotates by 45°. The motor will be at this-rest position until another command is give" to the system for further movement of the shaft in the desired direction.‘ APPLICATIONS OF SERVOMOTOR * pc servomotors find its applications in various domains. Some of them are given For very high voltage power systems, DC motors are preferred because they operate more efficiently than comparable AC servomotor > Ithas also found its application in inkjet printers:-and.RC helicopters It is used to drive conveyors used in Industrial manufacturing and assembling units to pass an object from one assembly station to another Ir is also used in a solar tracking system 5 DC servomotors are widely used in robots, toy cars and other position controlled devices 2 Widely used in radars, computers, robots, machine tools tracking system, process controllers etc. ADVANTAGES AND DISADVANTAGES OF SERVOMOTOR ages Et provides high output power relative to motor size and weight Encoder determines accuracy and résolution It produces high efficiency. Its efficiency can approach 90% at light loads; Ithas high torque to inertia ratio. It can rapidly accelerate loads Ithas "reserve" power. 2-3 times continuous power is for short periods Ithas "reserve" torque. 5-10 times rated torque is for short periods Motor stays cool. Current draws proportional to load Ithas high speed torque Tthas audibly quiet at high speeds and vibration free operation will occur vv YyryvYyYY~ Mechatronics Disadvantages NaN Vow VV v Motor develops peak power at higher speeds. Gearing often required Poor motor cooling. Ventilated motors are easily contaminated Design is complex. It requires encoder It requires "tuning" to stabilize feedback loop Motor can be damaged by sustained overload Motor "runs away" when something breaks. Safety circuits are required Brush wear out limits life to 2,000 hrs. Service is then required’ Peak torque is limited to a 1% duty cycle It has confusing choice of motors, encoders and servo-drives Power supply current is 10 times the average to use peak torque