Assosa University: College of Engineering, Department of Mechanical Engineering
Assosa University: College of Engineering, Department of Mechanical Engineering
Assosa University: College of Engineering, Department of Mechanical Engineering
COLLEGE OF ENGINEERING,
DEPARTMENT OF MECHANICAL ENGINEERING
INDIVIDUAL ASSIGNMENT: 1
COURSE: MECHATRONICS
Q.1. Discuss the various type of D.C Motors and control of D.C. motors. Write
the application in domestic use.
A DC motor (direct current motor).
A Motor is a machine that converts electrical energy into mechanical energy. There is no
difference between a DC motor and DC generator from a construction point of view. The only
difference is that the generators are usually operated in more protected locations and, therefore,
their construction is generally of the open type. On the other hand, motors are generally used in
locations where they are exposed to dust, moisture, fumes and mechanical damage. Thus, the
motor requires protective enclosures.
Types of Dc motors
The permanent magnet DC motor (also known as a PMDC motor) consists of an armature
winding as in case of a usual motor, but does not necessarily contain the field windings. The
construction of these types of DC motor are such that radially magnetized permanent magnets
are mounted on the inner periphery of the stator core to produce the field flux.
As the name suggests, in case of a separately excited DC motor the supply is given separately to
the field and armature windings. The main distinguishing fact in these types of DC motor is that,
the armature current does not flow through the field windings, as the field winding is energized
from a separate external source of DC current as shown in the figure beside.
C Self-Excited DC Motor
In case of self-excited DC motor, the field winding is connected either in series or in parallel or
partly in series, in parallel to the armature winding. Based on this, self-excited DC Motors can be
classified as:
Series Wound DC Motor In case of a series wound self-excited DC motor or simply series
wound DC motor, the entire armature current flows through the field winding as its connected
in series to the armature winding.
If the shunt field winding is only parallel to the armature winding and not the series field
winding then its known as short shunt DC motor or more specifically short shunt type compound
wound DC motor.
CONTROL OF DC MOTOR
Control of DC motor is any device that can manipulate the position, speed, or torque of a DC-
powered motor.
The power loss in the control resistance of DC series motor can be neglected because this control
method is utilized for a large portion of time for reducing the speed under light load condition. This
method of speed control is most economical for constant torque.
The combination of a rheostat shunting the armature and a rheostat in series with the armature is
involved in this method of speed control. The voltage applied to the armature is varies by
varying series rheostat R1. The exciting current can be varied by varying the armature shunting
resistance R2. This method of speed control is not economical due to considerable power losses
in speed controlling resistances. Here speed control is obtained over wide range but below
normal speed.
This is another method of increasing the speed by reducing the flux and it is done by lowering
number of turns of field winding through which current flows. In this method a number of
tapping from field winding are brought outside. This method is employed in electric traction.
Applications include:
There are several basic logic gates used in performing operations in digital systems. The
common ones are;
The Logic AND Function output is only true when all of its inputs are true, otherwise the output
is false The Logic AND Function function states that two or more events must occur together
and at the same time for an output action to occur. The order in which these actions occur is
unimportant as it does not affect the final result. For example, A & B = B & A. In Boolean
algebra the Logic AND Function follows the Commutative Law which allows a change in
position of either variable.
The AND function is represented in electronics by the dot or full stop symbol ( . ) Thus a 2-input
(A B) AND Gate has an output term represented by the Boolean expression A.B or just AB.
Here the two switches, A and B are connected together to form a series circuit. Therefore, in the
circuit above, both switch A AND switch B must be closed (Logic “1”) in order to put the lamp
on. In other words, both switches must be closed, or at logic “1” for the lamp to be “ON”.
As there are only two Switches, each with two possible states “open” or “closed”. Defining
Logic “0” as being when the switch is open and Logic “1” when the switch is closed.
Logic OR Function
The Logic OR function output is only true if one or more of its inputs are true, otherwise the
output is false
The Logic OR Function function states that an output action will become TRUE if either one
“OR” more events are TRUE, but the order at which they occur is unimportant as it does not
affect the final result.
Here the two switches A and B are connected in parallel and either Switch A OR Switch B can
be closed in order to put the lamp on. In other words, either switch can be closed, or at logic “1”
for the lamp to be “ON”.
Then this type of logic gate only produces and output when “ANY” of its inputs are present and
in Boolean Algebra terms the output will be TRUE when any of its inputs are TRUE.
PLC stands for “Programmable Logic Controller”. A PLC is a computer specially designed to
operate reliably under harsh industrial environments – such as extreme temperatures, wet, dry,
and/or dusty conditions. It is used to automate industrial processes such as a manufacturing
plant’s assembly line, an ore processing plant, or a wastewater treatment plant The term PLC
architecture refers to the design specification of the various PLC hardware and software
components and the how they interact with one another to form the overall PLC system. The
architecture of a PLC is based on the same principles of that used in standard computer
architecture. However, PLC architecture does differ because the design is based around
providing high reliability, immunity to harsh industrial environment, ease of maintenance and
access to large amounts of peripheral inputs and outputs.
An open architecture design allows the system to be connected easily to devices and programs
made by other manufactures. A closed architecture or proprietary system is one whose design
makes it more difficult to connect devices and programs made by other manufacturers. The
programmable logic controller is defined as a digital electronic device that uses a programmable
memory to store instructions and to implement functions such as logic, sequencing, timing,
counting and arithmetic words to control machines and processes.”
1 Glass Industry
2 Paper Industries
3 Process Automation Plants (e.g. mining, oil &gas)
The production of glass is an elaborate and sophisticated process so the companies involved
often use PLCs with the bus technology in its control mode. PRCs controllers have been in use in
the glass industry for decades. They are used largely to control the material ratio as well as to
process flat glasses.
Paper Industry
The paper industry, PLCs is used in various processes. These include controlling the machines
that produce paper products at high speeds.
Process Automation Plants (e.g. mining, oil &gas)
Manufacturing cement involves mixing various raw materials in a kiln. The quality of these raw
materials and their proportions significantly impact the quality of the final product. To ensure the
use of the right quality and quantities of raw materials, the accuracy of data regarding such
process variables is of the essence.
In the early development, an analog system, not containing a digital device like computer, in
which some of the signals sampled, was referred to as a sampled data system. With the advent of
digital computer, the term discrete-time system denoted a system in which all its signals are in a
digital coded form. Most practical systems today are of hybrid nature, i.e., contains both analog
and digital components. Before proceeding to any depth of the subject, we should first
understand the reason behind going for a digital control system. Using computers to implement
controllers has a number of advantages. Many of the difficulties involved in analog
implementation can be avoided. Few of them enumerated below.
a. Probability of accuracy or drift can be removed.
b. Easy to implement sophisticated algorithms.
c. Easy to include logic and nonlinear functions.
d. Re configurability of the controllers.
Logic control
Logic Control can be modeled using a state diagram which is a form of hierarchical state
machine. These state diagrams can also be combined with flow charts to provide a set
of computational semantics for describing complex control logic. This mix of state diagrams
and flow charts is illustrated in the figure on the right, which shows the control logic for a simple
stopwatch. The control logic takes in commands from the user, as represented by the event
named “START”, but also has automatic recurring sample time events, as represented by the
event named “TIC”.
Q.5 Enumerate the difference between a PLC and a personal computer (PC).
Programmable logic controller (PLC)
PLC stands for programmable logic control. It is computer designed to be used in industry. It
controls the different process and is programmed According to the operational requirement of
that process. And also PLC is a microprocessor based programming technique, which is used to
perform many functions in industrial process. Programmable logic controller operates similar to
the ordinary controller. But in this system different operation are performed by software. If we
want to change program it is only needed to change the program in the software. PLC takes input
instructions in the form of ladder diagram or computer software instructions. These instructions
are decoded in CPU and CPU provides differed signals to control or to operate many devices of
system.
PCs eventually developed features that put them in line with PLCs in terms of functionality. In
addition, they retained their robustness as well as customization due to the availability of card
slots and ports. The processing power of PCs was often greater than PLCs as they contained real-
time kernel, enabling it to perform time-critical tasks and implement control algorithms. PC has a
superior ability to perform monitoring/ supervising functions such as report generation, historical
trending, calculations and storage of data. Whatever may be the size and nature of the
applications, PC can play an important role. For small pilot projects, where the control is usually
undefined, the PC with its flexibility and true programmability is the proper tool real time
multitasking environment tailored for PC based control systems ensures that the information path
between field input/output modules and the host is always open or strictly speaking never closed
long enough to interfere with the process under control.
Q.6. what are the benefits of Mechatronics in industry? Mention application defense.
Mechatronic systems are used in different fields of application, e.g. industrial goods. Consumer
products and automotive equipment. While the term smart is elusive in precise definition, in the
engineering sense we mean the inclusion of elements such as logic, feedback, and computation
that in a complex design may appear to simulate human thinking processes
Production of parts and products of international standards gives better reputation and
return.
It serves effectively for high dimensional accuracy requirements.
It provides high degree of flexibility to modify or redesign the systems.
It provides excellent performance characteristics.
It Results in automation in production, assembly and quality control.
Mechatronic systems provide the increased productivity in manufacturing organization.
Reconfiguration feature by pre-supplied programs facilitate the low volume production.
It provides higher level of flexibility required for small product cycles.
It provides the possibility of remote controlling as well as centralized monitoring and
control. .
It has greater extend of machine utilization.
Higher life is expected by proper maintenance and timely diagnosis of the fault.
Mechatronic system have made it very easy to design process and products.
MECHATRONICS APPLICATIONS:
Smart consumer products: home security, camera, microwave oven, toaster,
dishwasher, laundry washer-dryer, climate control units, etc.
Medical: implant-devices, assisted surgery, haptic, etc.
Defense: unmanned air, ground, and underwater vehicles, smart munitions, jet engines,
etc.
Manufacturing: robotics, machines, processes, etc.
Automotive: climate control, antilock brake, active suspension, cruise control, air bags,
engine management, safety, etc.
Network-centric, distributed systems: distributed robotics, tele robotics,
Intelligent highways, etc.
Q.7 what are position sensors? Explain the working of Hall Effect sensors and
mention the advantages of it.
Position sensors are a vital component of many industrial processing set-ups and monitoring
equipment. Sensors are typically needed for quality control and ensuring safety. In some
commercial applications like consumer products, sensors provide the framework for some
functions. A position sensor is a sensor that facilitates measurement of mechanical position. Position
sensors play an increasing role in our daily lives. As their name implies, position sensors provide position
feedback. They are able to perform precise motion control, encoding and counting functions by
determining the presence or absence of a target or by detecting its motion, speed, direction or distance.
Magnetic sensors are solid state devices which generate electrical signals proportional to the
magnetic field applied on it. These electrical signals are then further processed by a user specific
electronic circuit to give the desired output.
An external magnetic field is used to activate these Hall Effect Sensors. When the magnetic flux
density in the vicinity of Sensor goes beyond a specific defined threshold, it is detected by the
Sensor. On detection, the Sensor generates an output voltage which is also known as Hall
Voltage.
Hall Effect Sensor is based on Hall Effect Principle. This principle says that when a conductor or
The static characteristic of the sensor refers to the relationship between the output and the input
of the sensor for the static input signal. Because both input and output are independent of time at
this time, the relationship between them is that the static characteristics of the sensor can be
described by an algebraic equation without time variables, or by using input as abscissa and
output as longitudinal coordinates. The main parameters that characterize the static
characteristics of the sensor are linearity, sensitivity, hysteresis, repeatability, drift and so on.
a) Linearity: refers to the degree to which the actual relationship curve between sensor
output and input deviates from the fitting line. It is defined as the ratio of the maximum
deviation between the actual characteristic curve and the fitting straight line in the full
range to the output value of the full range.
c) Hysteresis: The phenomenon that the input-output characteristic curve does not coincide
with the output characteristic curve becomes hysteresis when the input of the sensor
changes from small to large (positive stroke) and from large to small (reverse stroke). For
the input signal of the same size, the positive and negative stroke output signals of the
sensor are different in size.
e) Drift: Sensor drift refers to the change of sensor output over time when the input is
constant. This phenomenon is called drift. There are two reasons for the drift: one is the
sensor’s own structural parameters; the other is the surrounding environment (such as
temperature, humidity, etc.).
Dynamic characteristics refer to the output characteristics of the sensor when the input changes.
the dynamic characteristics of the sensor are often expressed by its response to some standard
input signals. This is because the response of the sensor to the standard input signal can be easily
obtained by experimental method, and there is a certain relationship between the response of the
sensor to the standard input signal and its response to any input signal. The most commonly used
standard input signals are step signal and sinusoidal signal, so the dynamic characteristics of the
sensor are often expressed by step response and frequency response.
a) Sensor linearity
Usually, the actual static characteristic output of the sensor is a curve rather than a straight line. a
fitting straight line is often used to approximate the actual characteristic curve. Linearity (non-
linear error) is a performance.
There are many ways to select the fitting line. If the theoretical straight line connected with zero
input and full range output points is used as the fitting line, or the theoretical straight line with
the least square deviation of each point on the characteristic curve is used as the fitting line, the
fitting line is called the least square fitting line.
b) Sensitivity of Sensors
Sensitivity refers to the ratio of output change (y) to input change (x) of the sensor under steady-
state operation. It is the slope of the output-input characteristic curve. If there is a linear
relationship between the output and input of the sensor, the sensitivity S is a constant. Otherwise,
it will vary with the input.
The dimension of sensitivity is the dimension ratio of output to input. For example, if the output
voltage of a displacement sensor changes to 200 mV when the displacement changes 1 mm, its
sensitivity should be expressed as 200 mV/mm.
c) Resolution of sensor
Resolution refers to the ability of the sensor to sense the smallest change in the measured value.
That is, if the input changes slowly from a non-zero value. When the input change value does not
exceed a certain value, the output of the sensor will not change, that is, the sensor can not
distinguish the change of the input. Only when the change of input exceeds the resolution will
the output change. Generally, the resolution of the sensor varies from point to point in the full
range, so the maximum change value of the input which can make the output step change in the
full range is often used as the index to measure the resolution.
A buse is a high-speed internal connection. Buses are used to send control signals and data
between the processor and other components.
The bus contains multiple wires (signal lines) with addressing information describing
the memory location of where the data is being sent or retrieved. Each wire in the bus carries a
bit(s) of information, which means the more wires a bus has, the more information it can address.
For example, a computer with a 32-bit address bus can address 4 GB of memory, and a computer
with a 36-bit bus can address 64 GB of memory.
Address bus - carries memory addresses from the processor to other components such as
primary storage and input/output devices. The address bus is unidirectional.
Data bus - carries the data between the processor and other components. The data bus
is bidirectional.
Control bus - carries control signals from the processor to other components. The control bus
also carries the clock's pulses. The control bus is unidirectional.
Q.10. Distinguish between a transducer and sensor.
Transducer
Transducer converts the physical quantity or nonelectrical into another signal or electrical signal
or is a device that changes the physical attributes of the non-electrical signal into an electrical
signal which is easily measurable. The process of energy conversion in the transducer is known
as the transduction.
The transduction completed into two steps. First by sensing the signal and then strengthening it
for further processing. It is quite difficult to determine the exact magnitude of the physical forces
like temperature, pressure, etc. However, if the physical force converted into an electrical signal,
then their value is easily measured with the help of the meter. The transducers convert the
physical forces into an electrical signal, which can easily be handled and transmitted for
measurement.
Sensor
Sensor will give an out put in the same format and transducer will convert the
measurement into an electrical signal.
The sensor is a device that measures the physical quantity (example heat, light, sound
etc.) in to an easily readable signal (voltage, current etc.)
the sensor senses the physical changes occur in the surrounding
The sensor is a device that measures the physical quantity (i.e. Heat, light, sound, etc.)
into an easily readable signal (voltage, current etc.). It gives accurate readings after
calibration.
Examples – The mercury used in the thermometer converts the measurand temperature
into an expansion and contraction of the liquid, which is easily measured, with the help of
a calibrated glass tube. The thermocouple also converts the temperature to an output
voltage which is measured by the thermometer
Basis for comparison between sensor and transducer
iii. The primary function of the sensor is to sense the physical changes, whereas the
transducer converts the physical quantities into an electrical signal.
The accelerometer, barometer, gyroscope are the examples of the sensor whereas thermistor, and
thermocouple is the examples of the transducer
Q.12 Explain the principle and application of proximity and light sensors.
Light sensors
A light sensor is a device that is used to detect light. There are different types of light sensors
such as photocell/photoresistor and photo diodes being used in manufacturing and other
industrial applications. Photoresistor is also called as light dependent resistor (LDR). It has a
resistor whose resistance decreases with increasing incident light intensity. It is made of a high
resistance semiconductor material, cadmium sulfide (CdS). The resistance of a CdS photoresistor
varies inversely to the amount of light incident upon it. Photoresistor follows the principle of
photoconductivity which results from the generation of mobile carriers when photons are
absorbed by the semiconductor material. Figure shows the construction of a photo resistor. The
CdS resistor coil is mounted on a ceramic substrate. This assembly is encapsulated by a resin
material. The sensitive coils electrodes are connected to the control system though lead wires. On
incidence of high intensity light on the electrodes, the resistance of resistor coil decreases which
will be used further to generate the appropriate signal by the microprocessor via lead wires.
Operating Principles
Inductive Proximity Sensors detect magnetic loss due to eddy currents that are generates on a
conductive surface by an external magnetic field. An AC magnetic field generates on the
detection coil, and changes in the impedance due to eddy currents generated on a metallic object
are detected. Proximity sensor is a non-contact sensor that detects the presence of an object (often
referred to as the “target”) when the target enters the sensor’s field. Depending on the type of proximity
sensor, sound, light, infrared radiation (IR), or electromagnetic fields may be utilized by the sensor to
detect a target. Proximity sensors are used in phones, recycling plants, self-driving cars, anti-aircraft
systems, and assembly lines. There are many types of proximity sensors, and they each sense targets in
distinct ways. The two most commonly used proximity sensors are the inductive proximity sensor and the
capacitive proximity sensor
Other methods include Aluminum-detecting Sensors, which detect the phase component of the
frequency, and All-metal Sensors, which use a working coil to detect only the changed
component of the impedance. There are also Pulse-response Sensors, which generate an eddy
current in pulses and detect the time change in the eddy current with the voltage induced in the
coil.
Capacitive Proximity Sensors detect changes in the capacitance between the sensing object and
the Sensor. The amount of capacitance varies depending on the size and distance of the sensing
object. An ordinary Capacitive Proximity Sensor is similar to a capacitor with two parallel plates,
where the capacity of the two plates is detected. One of the plates is the object being measured
(with an imaginary ground), and the other is the Sensor’s sensing surface. The changes in the
capacity generated between these two poles are detected.
The objects that can be detected depend on their dielectric constant, but they include resin and
water in addition to metals.
A. Brightness Control
In our mobile phone and laptops, we increasing and decreasing the resolution of the
screen light is varied by light sensors.
Ambient sensors are mostly used in electronic devices like mobiles, laptops and
computers.
These sensors are also used in different street light for the automatic control of light.
B. Security System
In different security circuits, light sensors are used. In shipping, these sensors provide
protection for the different products that are moving from one place to another.
Light sensors are installed in the cabin where the products are saved when someone tries
to open the door light sensor sense slight and sends a signal to the alarm connected with
it.
C. Agriculture
The light of the sun plying the significant rule in agriculture for the production of the
different crops.
Different food seed requires a different quantity of light, so it is important to know which part of
the land is under the sunlight