2 mechatronics
TRANSCRIPT
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Prepared byOnipede Bamidele O. and Omole, Femi O. 1Prototype Engineering Development Infrastructure (PEDI), Ilesa, Osun State
National Agency for Science and Engineering Infrastructure (NASENI)
MECHATRONICS: AN OVERVIEW
Mechatronics, the term coined in Japan in the 1970s, has evolved over the past
25 years and has led to a special breed of intelligent products.
Mechatronics is a natural stage in the evolutionary process of modern
engineering design. It is the synergetic integration of mechanical engineering
with electronics and intelligent computer control in the design and
manufacturing of industrial products and processes.
Mechatronics is an interdisciplinary field, in which the following disciplines act
together (see Figure (A) below):
Mechanical Systems (Mechanical Elements, Machines, and Precision
Mechanics);
Electronic Systems (Microelectronics, Power Electronics, Sensor and Actuator
Technology); and
Information Technology(Systems Theory, Automation, Software Engineering,
Artificial Intelligence).
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Prepared byOnipede Bamidele O. and Omole, Femi O. 2Prototype Engineering Development Infrastructure (PEDI), Ilesa, Osun State
National Agency for Science and Engineering Infrastructure (NASENI)
Figure (A): Mechatronics: Synergetic integration of different disciplines
WHY MECHATRONICS?
We have to ask ourselves, why is it so important for the Industry to keep the
know-how of their employees and staff permanently up-to-date. Why should
the Industry send participants for a short-term training program to a Centre of
Excellence, with Trainers who are certified according to international and
professional standard? The reasons are not far-fetched.
I. Continuous learning. This is essential because:i. Product Lifecycle
Innovations and trends reduce the lifecycle of a product dramatically.
Production systems have to be flexible to be able to react as fast as possible.
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Prepared byOnipede Bamidele O. and Omole, Femi O. 3Prototype Engineering Development Infrastructure (PEDI), Ilesa, Osun State
National Agency for Science and Engineering Infrastructure (NASENI)
ii. ProductivityNew trends and technological developments can increase the productivity and
your standing in the global market.
II. Automation technology. This is required because ofi. Globalization
The global market requests for availability, quality, reasonable prices and
services.
ii. ProductivityIncrease the Productivity by producing on a higher level of Automation. The
key factors of Productivity are:
Quality Time Costs
Mechatronics Training is important to be able to handle automated and
networked systems. To do so a new way of thinking and acting is required
Mechatronics.
The technological parts which have to be handled are Factory and Process
Automation.
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Prepared byOnipede Bamidele O. and Omole, Femi O. 4Prototype Engineering Development Infrastructure (PEDI), Ilesa, Osun State
National Agency for Science and Engineering Infrastructure (NASENI)
TYPES OF AUTOMATION
There are two parts of automation processes in industry.
Factory Automation
This is the handling of solid workpieces through-out the entire manufacturing
process, by means of which, in each step of the process, the shape, dimension,
orientation and material is known.
Process Automation
This is the handling of all flowing materials, fluids or powdery, in manual or
automated processes i.e. the production, transportation, treatment and
disposal. Mostly closed loop controllers are used within the Process
Technology to control pressure, level, flow, temperature etc.
Figure (B) shows both Factory and Process Automation Setup.
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Prepared byOnipede Bamidele O. and Omole, Femi O. 5Prototype Engineering Development Infrastructure (PEDI), Ilesa, Osun State
National Agency for Science and Engineering Infrastructure (NASENI)
Figure (B): Factory and Process Automation Setup
MECHATRONICS STRUCTURE
The training conception of Mechatronics is divided into three levels with the
focus on technology and competence.
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Prepared byOnipede Bamidele O. and Omole, Femi O. 6Prototype Engineering Development Infrastructure (PEDI), Ilesa, Osun State
National Agency for Science and Engineering Infrastructure (NASENI)
BASIC TECHNOLOGIES
The basic training technologies are:
Mechanics Electrics/Electronics Pneumatics Hydraulics Sensorics Controllers Robotics CAD/CAM/CNC IT
Partly Automation
This represents the production process steps of:
Storage/Retrieval Quality Transportation Processing Handling
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National Agency for Science and Engineering Infrastructure (NASENI)
Assembly
Fully Automation
This represents the interaction of the single production steps to an entire
production process. The focus here is on:
Installation and Commissioning Programming and Communication Maintenance and Trouble Shooting
Figure (C): Full Automation Setup
PLANNING AND DESIGN
This is the process involved in the arrangement of the laboratory. The
following points should be noted as a rule:
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National Agency for Science and Engineering Infrastructure (NASENI)
The laboratory should be symmetrical. No cables should lie around the floor naked. Good colour separation The laboratory should be beautiful and neat
INSTALLATION AND COMMISIONING
Installation involves the coupling of all station, components and parts. The
bringing together of all the separate units of any production line is called
Assembly.
Commissioning is the process of ensuring that all component parts are in good
working condition i.e. sensors, switches, and connections.
There are three types of commissioning:
Pneumatic commissioning: to ensure good regulation of air pressure,absence of all leaks.
Mechanical commissioning: to ensure the right alignment of allmechanical parts.
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National Agency for Science and Engineering Infrastructure (NASENI)
Electrical commissioning: to ensure good electrical connections of thewires and cables to the appropriate terminals. The driving voltage of the
setup is 24 Volts.
PROGRAMMING AND COMMUNICATION
DIGITAL TECHNOLOGY: LOGIC GATES
Logic gates are the basic building blocks of logic circuits and a computer.
Mechatronic systems have a central computational element as well as specific
logic functions implemented in hardware. A logic circuit consists of several
logic gates working together. Logic operations can be subdivided into two
categories, namely, combinational and sequential. In combinational logic
circuits, the logic gates are used to produce an output based on instantaneous
values of the inputs, whereas in the sequential logic circuits, the change in
output depends on the present state as well as the state before the changes in
input values, thus exhibiting memory behavior. Furthermore, the sequential
logic circuits can be synchronous or asynchronous. When the output changes
synchronously with a clock input, it is said to be synchronous. When the inputs
are read as soon as there is any change in it, it is called an asynchronous logic
circuit.
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Prepared byOnipede Bamidele O. and Omole, Femi O. 10Prototype Engineering Development Infrastructure (PEDI), Ilesa, Osun State
National Agency for Science and Engineering Infrastructure (NASENI)
There are three fundamental logic operations, namely AND, OR, and NOT
functions. Other logic operations are derived from these fundamental ones.
The AND gate symbol and its truth table are shown in Figure (D).
Input A Input B Output Q
0 0 0
0 1 0
1 0 0
1 1 1
Figure (D): Truth table and symbol for two input AND logic gate
The AND gate can have more than two inputs.
Figure (E) shows an OR gate. Here the output is 1 when either of the inputs or
both inputs are 1.
Figure (E): Truth table and symbol for two input OR logic gate
Input A Input B Output Q
0 0 0
0 1 1
1 0 1
1 1 1
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National Agency for Science and Engineering Infrastructure (NASENI)
The OR gate can also have more than two inputs.
Figure (F) shows an inverter, also known as a NOT gate. This gate takes one
input and simply inverts the logic, that is, a 1 input is returned as 0 output and
vice versa.
Figure (F): Truth table and symbol for NOT logic gate
Other common logic gates that are derived from these fundamental ones are
NAND, NOR, and Exclusive OR gates. NAND gate is a combination of AND and
NOT gates; NOR is a combination of OR and NOT gates, and Exclusive OR can
be generated with a combination of OR, NAND, and AND gates.
The logic functions and their implementation into hardware using gates is the
basic building block of a digital computer.
PROGRAMMING LANGUAGES
Programming languages for PLCs are described in IEC-1131-3 nomenclature:
LDLadder Diagram
Input Output
1 0
0 1
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National Agency for Science and Engineering Infrastructure (NASENI)
ILInstruction List (An Assembler) SFCSequential Functions Chart STStructured Text (similar to a high level language) FBDFunction Block Diagram
BIT, BYTE WORD PROCESSING IN MECHATRONICS
BIT: The simplest form of data is one bit, which can take one of the two values
0 or 1, and hence is called binary data. All information in modern digital
computers is stored in binary form.
BYTE: A fixed number of bits (usually 8), which can be treated by a computer as
a unit.
One byte = 8bits
One word = 2 bytes = 16 bits
Q (B, W) - Output (Byte, Word)
In the PLC, the first byte is for the station while the second is for the control
panel.
PROGRAMS IN A CPU
A CPU will principally run two different programs:
The operating system and
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Prepared byOnipede Bamidele O. and Omole, Femi O. 14Prototype Engineering Development Infrastructure (PEDI), Ilesa, Osun State
National Agency for Science and Engineering Infrastructure (NASENI)
User Program
The user program can be created and downloaded to the CPU. It contains all
the functions required to process specific automation task. The tasks of the
user program include:
Processing process data (for example, generating logical links of binary
signals, fetching and evaluating analog signals, specifying binary signals for
output, output of analog values)
Reaction to interrupts
Handling disturbances in the normal program cycle.
Blocks in the User Program
The STEP 7 programming software allows the structuring of the user program,
in other words to break down the program into individual, self-contained
program sections. This has the following advantages:
Extensive programs are easier to understand.
Individual program sections can be standardized.
Program organization is simplified.
It is easier to make modifications to the program.
Debugging is simplified since separate sections can be tested.
Commissioning of the system is made much easier.
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National Agency for Science and Engineering Infrastructure (NASENI)
The program sections of a structured user program correspond to these
individual tasks and are known as the Blocks of a program.
Block Types
There are several different types of blocks you can use within an S7 user
program:
Block Brief Description of Function
Organization Blocks (OB) OBs determine the structure of the user program.
System Function Blocks
(SFB) and System Functions
(SFC)
SFBs and SFCs are integrated in the S7 CPU and allow the
access to some important system functions.
Function Blocks (FB) FBs are blocks with a "memory" which can be programmed
by the user.
Functions (FC) FCs contain program routines for frequently used functions.
Instance Data Blocks
(Instance DB)
Instance DBs are associated with the block when an FB/SFB
is called. They are created automatically during compilation.
Data Blocks (DB) DBs are data areas for storing user data. In addition to the
data that are assigned to a function block, shared data can
also be defined and used by any blocks.
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National Agency for Science and Engineering Infrastructure (NASENI)
OBs, FBs, SFBs, FCs, and SFCs contain sections of the program and are
therefore also known as Logic Blocks. The permitted number of blocks per
block type and the permitted length of the blocks is CPU-specific.
Organization Blocks (OBs) represent the interface between the operating
system and the user program. They are called by the operating system; and
control cyclic and interrupt-driven program execution, startup behavior of the
PLC and error handling. Organization Blocks can be programmed to determine
CPU behaviour.
STRUCTURAL PROGRAMMING
The entire user program can be written in OB1 (linear programming). This is
only advisable with simple programs written for the S7-300 CPU and requiring
little memory. Complex automation tasks can be controlled more easily by
dividing them into smaller tasks reflecting the technological functions of the
process. These tasks are represented by corresponding program sections,
known as the Blocks (Structured Programming).
Let the programming begin!