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

8
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
9 10

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
13 14

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
15 16
 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
17 18

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
21
 The disturbance input is measured and fed into the controller
22

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

25
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

27 28
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