Fluid Automation - Unit 1a

Unit 1a – Basic principles of automatic systems
Mechatronic Engineering: Fluid Automation

BASIC PRINCIPLES OF AUTOMATIC SYSTEMS: General
Automatic systems are widely used in all sectors:

from production lines
to transportation and handling,
civil applications,
and many more.
REQUIRED CHARACTERISTICS
High movement capacity, and thus short cycle times
High accuracy in positioning and actions performed
Durability
High reliability
Limited cost.
Mechatronic Engineering – Fluid Automation

BASIC PRINCIPLES OF AUTOMATIC SYSTEMS: General
To satisfy these requirements, automatic systems draw on many

technologies which are integrated together in constructing the
system.
Pneumatics is one of the technologies that is commonly used in

automatic systems, along with mechanics, electronics,
electromechanics and hydraulics.

BASIC PRINCIPLES OF AUTOMATIC SYSTEMS: STRUCTURE
STRUCTURE OF AUTOMATIC SYSTEMS
The system produces actions (movements and/or forces or torques)

when managed by an operator.
The operator manages the system via a man-machine interface
consisting of a keypad or a set of pushbuttons on a control panel.
These elements (called input elements) are used to give the main
commands (start, stop, emergency shutoff, etc.) in the form of
signals sent to the control unit.
STRUCTURE OF AUTOMATIC SYSTEMS
In the control unit, the signals are processed using the logic adopted
for the unit, thus generating command signals for the
actuators (or motors).
The movements or forces/torques produced in this way are detected

by sensors or limit switches and sent back to the control unit.

TYPES OF ACTUATION
The main types of actuation system used in automatic systems are as
follows:
Mechanical
Electric
Hydraulic
Pneumatic
Each of these technologies has specific characteristics that make it

suitable for certain applications.
A complex automatic machine will thus employ all or almost all of
them at the same time.
MECHANICAL ACTUATION
These systems consist of: cam devices, articulated mechanisms:
Advantages:
 Very precise execution of
 a certain law of motion
 Extremely high speed
 Perfectly repeatable cycles.
Drawbacks:
As these systems are rigid (with little flexibility), they must be
redesigned and rebuilt if the law of motion is to be changed.
These systems are also relatively costly.

ELECTRIC ACTUATION
An electric motor actuates the element to be moved, either directly
or via motion transmission elements (speed reducers).
Advantages:
Completely flexible systems that can follow laws of motion varying
from cycle to cycle, thanks to the use of controllable electric motors.
It is thus possible to use:
Direct current motors, brushless motors, stepper motors, etc.
Drawbacks:
Relatively costly systems.
Speeds are less than those of cycles with mechanical systems.

HYDRAULIC ACTUATION
Characteristics:
 Good controllability
 Variable laws of motion can thus be executed.
Hydraulic actuators are chiefly used for high powers, given that
they operate at very high pressures, from 80 to 500 bar.
(forces developed typically range from 500 to 200,000 daN).
Very high power-to-weight ratio, higher than the corresponding
electric motors of the same power.
 Can be used to advantage in applications on earthworking
machines.
These systems also involve rather high cost.

PNEUMATIC ACTUATION
Characteristics:
 Lower pressure than hydraulic actuators (from 4 to 10 bar)
 Small/medium forces are developed (typically from 2 to 4000

daN).
Digital systems (more common)

Proportional systems with very high performance (less common)
 Good ratio of developed power to weight (lower than that of

hydraulic systems, but higher than electric systems).
 Limited cost – can be integrated effectively in low cost
automation systems.
APPLICATIONS OF EACH TECNOLOGY
Input elements Control Unit Actuators Movements /

External Electronic Electromechanical Forces, torques
Electric or pneumatic Relay Interfaces Hydraulic
commands
Pneumatic logic Pneumatic
Sensors and limit switches

Electromechanical
Electronics
Pneumatic
Actuators are available with all technologies: electromechanical,

hydraulic and pneumatic.
Naturally, which technology is used will depend on the end user’s
needs and the type of actuation required.

APPLICATIONS OF EACH TECHNOLOGY

Electric or pneumatic Relay Interfaces
commands Hydraulic

Electromechanical
Electronics
Pneumatic

commands Hydraulic

Electromechanical
Electronics
Pneumatic
There are fewer types of control unit:

Electronic devices
Electromechanical relays
Pneumatic logic valves.
There are no hydraulic devices in this category, as hydraulics is
used only for providing power or controlling it directly.

commands Hydraulic

Electromechanical
Electronics
Pneumatic
Electronic devices are the most common.

They include electronic logic circuits and
programmable units.
Programmable Logic Controllers (PLCs) and
personal computers (PCs) are widely used for
control.
AUTOMATION WITH PROGRAMMABLE LOGIC

commands

Electromechanical
Electronics
Pneumatic
Electromechanical relays are a conventional way of constructing

hard-wired control circuits, though their applications are currently
limited to relatively small systems and safety operations where it is
better not to rely on software programs.
Standard EN60204-1
HARD-WIRED AUTOMATION

commands Hydraulic

Electromechanical
Electronics
Pneumatic
Pneumatic logic elements are used in small systems where fully

pneumatic machines must be used because of environmental
considerations (risk of explosion, excessive moisture, etc.) or for
cost reasons, as they are more economical.
HARD-WIRED AUTOMATION


commands Hydraulic

Electromechanical
Electronics
Pneumatic
Interface elements make it possible to connect low power signal

control elements and high power signal actuators, and also to
convert from one technology to another.
Examples of interface elements: solenoid

valves used to change from electrical
signals to pneumatic signals.
commands

Electromechanical
Electronics
Pneumatic
Most sensors and limit switches are electronic or

electromechanical, but there are also pneumatic
units with the same functions.
Which type of sensor is selected often depends on
the type of control unit used.
Systems may feature electric limit switches,
electromechanical limit switches, pneumatic limit
switches, magnetic limit switches, electropneumatic limit
switches, fluidic sensors, optical sensors, etc.
commands

Electromechanical
Electronics
Pneumatic
Input elements may be electric or pneumatic. Which are used

depends entirely on whether the control unit to which they are
connected is electric or pneumatic.
Pushbuttons and selectors of both types are available, featuring the
same functions and often having the same typical package
dimensions. Mechatronic Engineering – Fluid Automation
SUMMARY
Actuation unit (power unit, operating unit): the part of the
automatic system that, by means of suitable actuators,
physically performs the operation to be automated.
This is the unit tasked with carrying out actuations and
movements; it can can develop forces and torques.
It receives orders (commands) from the control unit.
THE MUSCLES OF THE SYSTEM

SUMMARY
Control unit (processing unit): this is the part
of the automatic system tasked with
coordinating all of the operations required for
automation.
It receives signals from the system’s input
elements (pushbuttons, selectors, etc.) and
sensors (limit switches).
It issues orders and commands for the
actuation unit.
THE BRAIN OF THE SYSTEM

SUMMARY
Interface unit (interface, communication unit): includes all of the
elements whereby information can be exchanged between control
unit and actuators.
Control unit Actuators
Valves, solenoid valves
Control unit Actuators

Sensors, limit switches

BASIC PRINCIPLES OF AUTOMATIC SYSTEMS: ORGANIZATION
TIME-BASED AND EVENT-BASED AUTOMATIC

SYSTEMS
TIME-BASED AUTOMATIC SYSTEMS: Operations are

performed when given periods of time have passed.
EVENT-BASED AUTOMATIC SYSTEMS: Orders are issued

only when the operations associated with them have been carried
out (i.e., when an actuator moves, a gripper closes, etc.).

TIME-BASED AUTOMATIC SYSTEMS

Block diagram of a time-based automatic system
Actuation takes place after a certain time has
passed.
Actuation unit The basic element of the control unit is a
periodic pulse generator.
Actuators
Control block
Time-
Valves Input
based
Distributors control elements
Operator
unit
Orders

Block diagram of a time-based automatic system
The sequence of pulses results in a periodic
signal map.
Actuation unit This map can be used to periodically
produce control pulses for the actuators.
Actuators
Control block
Valves Time-
based Input
Distributors
control elements Operator
unit
Orders

OPERATION:
The control unit periodically emits signals.
The power section (valves and actuators) receives signals for
carrying out movements from the control unit.
No signals are sent in the opposite direction, from the power
section to the control unit.
The system is an open loop type:
the control unit sends orders, but does not receive signals
confirming that the orders have been carried out.
APPLICATION: systems where time is a fundamental parameter

(processing industry equipment).

EVENT-BASED AUTOMATIC SYSTEMS
Block diagram of an event-based automatic system
Orders are issued only when certain events
take place, i.e., when certain operations are
performed.
Actuators Limit switches Misc. external sensors

Enabling
signals
Valves Event-
Distributori based Control
Distributors
control unit panel Operator
Orders Control block


Block diagram of an event-based automatic system
A double interconnection is needed between
the control unit and actuation unit.
The system continuously checks that orders
have been carried out.
Actuators Limit switches Misc. external sensors

Enabling
signals
Valves Event-
Distributori Control
based
Distributors panel
control unit Operator
Orders Control unit


OPERATION:
 The control unit emits signals (orders, commands).
 The power section (valves and actuators) receives signals for
carrying out movements from the control unit: moving an
actuator, opening a gripper, etc. (or events).
 The control unit receives enabling signals for the events from
the sensors and limit switches.
This is a closed loop system: the control unit sends orders and
receives signals (enabling signals) confirming that orders have
been carried out.
APPLICATION: Mechanical and manufacturing industry

(automation of discontinuous processes).
HARD WIRED AND PROGRAMMABLE LOGIC

Performing automatic operations associated with specific
movements and actuations establishes a sequence of stages that
makes up the automatic cycle.
Designing an automatic system consists of defining the control
unit logic that can satisfy the system’s movement specifications.
Hard wired logic control unit Programmable logic unit

HARD WIRED LOGIC AUTOMATIC SYSTEMS

These systems feature logic elements connected to each other by
electric wires or lines in circuits that can perform a certain cycle
rigidly.
Signals are transferred from one element to another to perform the
required operations.
Hard wired logic control unit
To change the cycle, the circuit must be

reconfigured by changing the
connections.

PROGRAMMABLE LOGIC AUTOMATIC SYSTEMS

These systems feature programmable control units: programmable
logic controllers (PLCs) or personal computers equipped with
control cards.
They make it possible to set up flexible cycles, to produce several
products on the same line, to introduce product changes over time,
…
Programmable logic control unit
The cycle can be changed by

modifying the program stored in
the controller.

DIGITAL AND PROPORTIONAL AUTOMATIC SYSTEMS

Digital systems: operate at Proportional systems
discrete levels. (analog): use the signal level
Presence or absence of present at a given instant.
signals, on-off signal, all or Actuations varying in level
nothing signal. can be performed:
continuous force regulation.
Component operation Component

is defined only through operation is based on
discrete signal states. a continuous signal
level.
SIGNAL TYPES
On
signal
signal
signal
Off
time time time
On-Off signal Proportional Digital signal

signal (analog)

DIGITAL AUTOMATIC SYSTEMS
In these systems, only certain discrete signal levels are important.

Normally, systems use two levels: presence-absence, ON-OFF, all
or nothing signal.
Signals in digital automatic systems are processed according to the
rules of binary logic (logical algebra or Boolean algebra).
In Boolean algebra, presence is designated by 1 and absence by 0.

The signal in an electric or pneumatic line can have only two
possible states, 1 or 0.
The presence of pressure in a pneumatic line produces state 1,
while its absence produces state 0.

PROPORTIONAL AUTOMATIC SYSTEMS

These systems use the signal level present at a given instant.
If, for example, the pressure signal is used, every variation in the
pressure signal occurring in a proportional system represents a
signal variation, and the system will react by changing its behavior
accordingly.
A proportional system can carry out actuations that vary in level:
continuous gripper clamping force regulation, cylinder rod
positioning (force control, position control).
Limit: signal noise (accidental variability which causes the signal
to vary), interference. Interference is interpreted as an explicit
request for orders.

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Unit 1a – Basic principles of automatic systems

Mechatronic Engineering: Fluid Automation

Automatic systems are widely used in all sectors:

High accuracy in positioning and actions performed

Mechatronic Engineering – Fluid Automation

To satisfy these requirements, automatic systems draw on many

Pneumatics is one of the technologies that is commonly used in

Mechatronic Engineering – Fluid Automation

STRUCTURE OF AUTOMATIC SYSTEMS

The system produces actions (movements and/or forces or torques)

STRUCTURE OF AUTOMATIC SYSTEMS

The movements or forces/torques produced in this way are detected

Mechatronic Engineering – Fluid Automation

Each of these technologies has specific characteristics that make it

 a certain law of motion

 Extremely high speed

 Perfectly repeatable cycles.

Mechatronic Engineering – Fluid Automation

Mechatronic Engineering – Fluid Automation

 Variable laws of motion can thus be executed.

Mechatronic Engineering – Fluid Automation

 Small/medium forces are developed (typically from 2 to 4000

Digital systems (more common)

 Good ratio of developed power to weight (lower than that of

APPLICATIONS OF EACH TECNOLOGY

Input elements Control Unit Actuators Movements /

Sensors and limit switches

Actuators are available with all technologies: electromechanical,

Mechatronic Engineering – Fluid Automation

APPLICATIONS OF EACH TECHNOLOGY

Sensors and limit switches

Mechatronic Engineering – Fluid Automation

Sensors and limit switches

There are fewer types of control unit:

Mechatronic Engineering – Fluid Automation

Sensors and limit switches

Electronic devices are the most common.

APPLICATIONS OF EACH TECHNOLOGY

Sensors and limit switches

Electromechanical relays are a conventional way of constructing

APPLICATIONS OF EACH TECHNOLOGY

Sensors and limit switches

Pneumatic logic elements are used in small systems where fully

Mechatronic Engineering – Fluid Automation

APPLICATIONS OF EACH TECHNOLOGY

Sensors and limit switches

Interface elements make it possible to connect low power signal

Examples of interface elements: solenoid

Sensors and limit switches

Most sensors and limit switches are electronic or

Sensors and limit switches

Input elements may be electric or pneumatic. Which are used

THE MUSCLES OF THE SYSTEM

Mechatronic Engineering – Fluid Automation

THE BRAIN OF THE SYSTEM

Mechatronic Engineering – Fluid Automation

Control unit Actuators

Mechatronic Engineering – Fluid Automation

TIME-BASED AND EVENT-BASED AUTOMATIC

TIME-BASED AUTOMATIC SYSTEMS: Operations are

EVENT-BASED AUTOMATIC SYSTEMS: Orders are issued

Mechatronic Engineering – Fluid Automation

TIME-BASED AUTOMATIC SYSTEMS