Manufacturing Controls

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Manufacturing Controls

• FALL 2001
•  

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Manufacturing Controls 20-IND-475-001 

• TIME 1100--1215 PM, Tuesday and Thursday
  Room 617 ERC
• INSTRUCTOR Professor Ernest L. Hall, P.E. Geier
  Professor of Robotics
• PHONE [phone], Email Ernie.Hall_at_uc.edu
• OFFICE HOURS 100--200 and 330--430 PM, TH,
  681 or 508 Rhodes
• WWW http//www.eng.uc.edu/elhall/mc.html
• TEXT Devdas Shetty and Richard A. Kolk,
  Mechatronics System Design, PWS Publishing,
  Boston.
• NOTES www.robotics.uc.edu/MC2001/

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Course objective

• To provide a broad basis for understanding modern
  digital control theory for manufacturing
• with enough detailed examples to provide
  practical experience in understanding stability
  and tuning of digital motion controllers using
  modern design tools such as Matlab.

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Syllabus

• DATE TOPIC NOTES
• 1. Sep. 20 Mechatronics Design Process Ch. 1
• 2. Sep. 25 System Modeling and Simulation Ch. 2
• 3. Sep. 27 Laplace Transforms and Transfer
  Functions Ch. 2
• 4. Oct. 2 Electrical Examples Ch.2, Notes
• 5. Oct. 4 Mechanical Examples Ch.2, Notes
• 6. Oct. 9 Thermal and Fluid Examples, QUIZ 1
  (Take Home)
• 7. Oct. 11 Sensors and Transducers Ch. 3
• 8. Oct. 16 Advanced MATLAB
• 9. Oct. 18 Analog and Digital Sensing Ch. 3,
  Notes
• 10. Oct. 23 Actuating Devices Ch. 4
• 11. Oct. 25 DC Motor Model Ch. 4,
  Notes
• 12. Oct. 30 Boolean Logic Ch. 5
• 13. Nov. 1 Programmable Logic Controllers Ch.
  5, Notes
• 14. Nov. 6 Stability and Compensators, P, PI and
  PD Ch. 6
• 15. Nov. 8 PID Controllers Ch. 7
• 16. Nov. 13 QUIZ 2 (In Class - Open Book)
• 17. Nov. 15 Practical and Optimal Compensator
  Design Ch. 8
• 18. Nov. 20 Frequency Response Methods Ch. 9,
  Notes

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Grading System

• FG .2(Q1 Q2 Q3 F HW)
• Where
• FG Final grade
• Qi Quiz i
• F Final exam
• HW Homework. 

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Note to Students

• You are expected to attend class, read the text,
  and use the computer. Computer accounts and Email
  are required. You will find MATLAB essential for
  some of the homework. The syllabus topics are
  guidelines and may be adapted as required to
  improve your understanding during the quarter.

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Todays objective

• To provide an introduction to systems theory and
  the use of Matlab by studying a simple example,
  the flexible link pendulum.

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System

• Human not yet fully understood
• Machine Linear and non-linear systems theory
• Man-Machine Best of both
• Has both input and output - normally

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Architecture of System

• Uncontrollable
• Example - sun

Plant
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Architecture of System

• Unobservable
• Example black hole

Plant
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• Non-servo system

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Feedback Control

• Feedback system measurements compared to input
  and error used to drive plant

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Digital Motion Control

• Motion control is one of the technological
  foundations of industrial automation.
• motion of a product
• path of a cutting tool
• motion of an industrial robot arm conducting seam
  welding
• motion of a parcel being moved from a storage bin
  to a loading dock by a shipping cart
• The control of motion is a fundamental concern.

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Control theory

• Control theory is a foundation for many fields,
  including industrial automation. The concept of
  control theory is so broad that it can be used in
  studying
• the economy
• human behavior
• spacecraft design
• industrial robots
• Automated guided vehicles
• Motion control systems often play a vital part
  of product manufacturing, assembly, and
  distribution.

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Mechatronics

• Motion Control is defined by the American
  Institute of Motion Engineers as
• "The broad application of various technologies to
  apply a controlled force to achieve useful motion
  in fluid or solid electromechanical systems."
• The field of motion control can also be
  considered as mechatronics.
• "Mechatronics is the synergistic combination of
  mechanical and electrical engineering, computer
  science, and information technology, which
  includes control systems as well as numerical
  methods used to design products with built-in
  intelligence."

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Components

• The components of a typical servo controlled
  motion control system may include
• an operator interface
• motion control computer
• control compensator
• electronic drive amplifiers
• Actuator
• Sensors
• Transducers
• and the necessary interconnections.
• The actuators may be powered by
  electro-mechanical, hydraulic or pneumatic or a
  combination of these power sources.

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Motion Control Example

• Consider the simple pendulum shown that has been
  studied for more than 2000 years.
• Aristotle first observed that a bob swinging on a
  string would come to rest, seeking a lower state
  of energy.
• Later, Galileo Galilee made a number of
  incredible, intuitive inferences from observing
  the pendulum.
• Galileos conclusions are even more impressive
  considering that he made his discoveries before
  the invention of calculus.

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Flexible Link Pendulum

• The pendulum may be described as a bob with mass,
  M, and weight given by WMg, where g is the
  acceleration of gravity, attached to the end of a
  flexible cord of length, L as shown.
• When the bob is displaced by an angle q, the
  vertical weight component causes a restoring
  force to act on it.
• Assuming that viscous damping, from resistance in
  the medium, with a damping factor, D, causes a
  retarding force proportional to its angular
  velocity, w, equal to D??.
• Since this is a homogeneous, unforced system, the
  starting motion is set by the initial conditions.
  Let the angle at time q(t0) be 45 ?.
• For definiteness let the weight, W 40 lbs., the
  length, L 3 ft, D 0.1 (lb.s) and g32.2
  (ft/s2).

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Free Body Diagram

• The analysis is begun by drawing a free body
  diagram of the forces acting on the mass. We
  will use the tangent and normal components to
  describe the forces acting on the mass. The free
  body diagram shown and Newton's second law are
  then used to derive a differential equation
  describing the dynamic response of the system.
• Forces may be balanced in any direction, however,
  a particularly simple form of the equation for
  pendulum motion can be developed by balancing the
  forces in the tangential direction

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The tangential acceleration is given in terms
of the rate of change of velocity or arc length
by the equation
Since the arc length, s, is given by
Substituting s into the differential in
Equation 3 yields
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System

• This equation may be said to describe a system.
• While there are many types of systems, systems
  with no output are difficult to observe, and
  systems with no input are difficult to control.
• To emphasize the importance of position, we can
  describe a kinematic system, such as y T(x).
• To emphasize time, we can describe a dynamic
  system, such as g h(f(t)).
• Equation 7 describes a dynamic response. The
  differential equation is non-linear because of
  the sin q term.

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Linear approach modeling
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Simple Harmonic Motion
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Now try it!

• Use Matlab to solve the pendulum.
• Just open a new workspace in Matlab.
• Copy the sample program.
• Run the m-file.

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Homework 1

• Now capture your Matlab program and output and
  format it on a Word page. Put you name on the
  page and turn it in to me as your first homework
  assignment.