MECHATRONICS MECHATRONICS ELECTRONIC CONTROL SYSTEMS IN MECHANICAL ELECTRONIC CONTROL SYSTEMS IN MECHANICAL AND ELECTRICAL ENGINEERING AND ELECTRICAL ENGINEERING WILLIAM BOLTON WILLIAM BOLTON SEVENTH EDITION SEVENTH EDITION M E C H AT RO N I C S F01 Mechatronics 50977 Contents.indd 30/08/2018 07:09 www.ebookslides.com At Pearson, we have a simple mission: to help people make more of their lives through learning We combine innovative learning technology with trusted content and educational expertise to provide engaging and effective learning experiences that serve people wherever and whenever they are learning From classroom to boardroom, our curriculum materials, digital learning tools and testing programmes help to educate millions of people worldwide – more than any other private enterprise Every day our work helps learning flourish, and wherever learning flourishes, so people To learn more, please visit us at www.pearson.com/uk F01 Mechatronics 50977 Contents.indd 30/08/2018 07:09 www.ebookslides.com MECHATRONICS ELECTRONIC CONTROL SYSTEMS IN MECHANICAL AND ELECTRICAL ENGINEERING Seventh Edition William Bolton Harlow, England • London • New York • Boston • San Francisco • Toronto • Sydney Dubai • Singapore • Hong Kong • Tokyo • Seoul • Taipei • New Delhi Cape Town • São Paulo • Mexico City • Madrid • Amsterdam • Munich • Paris • Milan F01 Mechatronics 50977 Contents.indd 30/08/2018 07:09 www.ebookslides.com Pearson Education Limited KAO Two KAO Park Harlow CM17 9NA United Kingdom Tel: +44 (0)1279 623623 Web: www.pearson.com/uk First published 1995 (print) Second edition published 1999 (print) Third edition published 2003 (print) Fourth edition published 2008 (print) Fifth edition published 2011 (print and electronic) Sixth edition published 2015 (print and electronic) Seventh edition published 2019 (print and electronic) © Pearson Education Limited 2015, 2019 (print and electronic) The right of William Bolton to be identified as author of this work has been asserted by him in accordance with the Copyright, Designs and Patents Act 1988 The print publication is protected by copyright Prior to any prohibited reproduction, storage in a retrieval system, distribution or transmission in any form or by any means, electronic, mechanical, recording or otherwise, permission should be obtained from the publisher or, where applicable, a licence permitting restricted copying in the United Kingdom should be obtained from the Copyright Licensing Agency Ltd, Barnard’s Inn, 86 Fetter Lane, London EC4A 1EN The ePublication is protected by copyright and must not be copied, reproduced, transferred, distributed, leased, licensed or publicly performed or used in any way except as specifically permitted in writing by the publishers, as allowed under the terms and conditions under which it was purchased, or as strictly permitted by applicable copyright law Any unauthorised distribution or use of this text may be a direct infringement of the author’s and the publisher’s rights and those responsible may be liable in law accordingly All trademarks used herein are the property of their respective owners The use of any trademark in this text does not vest in the author or publisher any trademark ownership rights in such trademarks, nor does the use of such trademarks imply any affiliation with or endorsement of this book by such owners Pearson Education is not responsible for the content of third-party internet sites ISBN: 978-1-292-25097-7 (print) 978-1-292-25100-4 (PDF) 978-1-292-25099-1 (ePub) British Library Cataloguing-in-Publication Data A catalogue record for the print edition is available from the British Library Library of Congress Cataloging-in-Publication Data Names: Bolton, W (William), 1933- author Title: Mechatronics : electronic control systems in mechanical and electrical engineering / William Bolton Description: Seventh edition | Harlow, England ; New York : Pearson Education Limited, 2019 | Includes bibliographical references and index Identifiers: LCCN 2018029322| ISBN 9781292250977 (print) | ISBN 9781292251004 (pdf) | ISBN 9781292250991 (epub) Subjects: LCSH: Mechatronics Classification: LCC TJ163.12 B65 2019 | DDC 621—dc23 LC record available at https://urldefense.proofpoint.com/v2/url?u=https-3A lccn.loc.gov_2018029322&d=DwIFAg&c=0YLnzTkW OdJlub_y7qAx8Q&r=eK0q0-QqUPIJD1OLTc7YiWdHxmNowNBMcvK9N3XeA-U&m=KkECpIRxvUd6hHO4IgYQ39O8Wnj16yu FhTNaAb0czTk&s=d_M15Lwv7uWaxVKsm14kfkQ5Quu9-ZHwFQvuouRdve8&e= 10 23 22 21 20 19 Print edition typeset in 10/11 pt Ehrhardt MT Pro by Pearson CSC Printed and bound in Malaysia NOTE THAT ANY PAGE CROSS REFERENCES REFER TO THE PRINT EDITION F01 Mechatronics 50977 Contents.indd 30/08/2018 07:09 Contents Preface xi I Introduction 1 Introducing mechatronics 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Chapter objectives What is mechatronics? The design process Systems Measurement systems Control systems Programmable logic controller Examples of mechatronic systems Summary Problems II Sensors and signal conditioning Sensors and transducers 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 Chapter objectives Sensors and transducers Performance terminology Displacement, position and proximity Velocity and motion Force Fluid pressure Liquid flow Liquid level Temperature Light sensors Selection of sensors Inputting data by switches Summary Problems F01 Mechatronics 50977 Contents.indd 3 21 22 26 27 29 31 31 31 32 37 54 57 57 61 62 63 69 70 71 74 75 Signal conditioning 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 Chapter objectives Signal conditioning The operational amplifier Protection Filtering Wheatstone bridge Pulse modulation Problems with signals Power transfer Summary Problems Digital signals Chapter objectives 4.1 Digital signals 4.2 Analogue and digital signals 4.3 Digital-to-analogue and analogue-to-digital converters 4.4 Multiplexers 4.5 Data acquisition 4.6 Digital signal processing 4.7 Digital signal communications Summary Problems Digital logic 5.1 5.2 5.3 5.4 Chapter objectives Digital logic Logic gates Applications of logic gates Sequential logic Summary Problems 78 78 78 79 90 91 92 97 98 100 101 101 103 103 103 103 107 113 114 116 118 119 120 121 121 121 122 130 135 143 143 30/08/2018 07:09 www.ebookslides.com vi CONTENTS Data presentation systems 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 Chapter objectives Displays Data presentation elements Magnetic recording Optical recording Displays Data acquisition systems Measurement systems Testing and calibration Summary Problems III Actuation Pneumatic and hydraulic actuation systems 7.1 7.2 7.3 7.4 7.5 7.6 7.7 Chapter objectives Actuation systems Pneumatic and hydraulic systems Directional control valves Pressure control valves Cylinders Servo and proportional control valves Process control valves Summary Problems Mechanical actuation systems 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 Chapter objectives Mechanical systems Types of motion Kinematic chains Cams Gears Ratchet and pawl Belt and chain drives Bearings Electromechanical linear actuators Summary Problems F01 Mechatronics 50977 Contents.indd 146 146 146 147 152 157 157 162 166 169 171 172 175 177 177 177 177 181 186 188 192 193 198 198 201 201 201 202 204 208 210 214 214 216 218 219 220 Electrical actuation systems 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 Chapter objectives Electrical systems Mechanical switches Solid-state switches Solenoids Direct current motors Alternating current motors Stepper motors Direct current servomotors Motor selection Summary Problems 222 222 222 222 224 231 232 241 243 250 251 255 255 IV Microprocessor systems 257 10 Microprocessors and microcontrollers 259 10.1 10.2 10.3 10.4 10.5 Chapter objectives Control Microprocessor systems Microcontrollers Applications Programming Summary Problems 11 Assembly language 11.1 11.2 11.3 11.4 11.5 11.6 Chapter objectives Languages Assembly language programs Instruction sets Subroutines Look-up tables Embedded systems Summary Problems 12 C language Chapter objectives 12.1 Why C? 12.2 Program structure 259 259 259 270 296 297 300 300 301 301 301 302 304 317 321 324 327 328 329 329 329 329 30/08/2018 07:09 www.ebookslides.com vii CONTENTS 12.3 12.4 12.5 12.6 12.7 12.8 Branches and loops Arrays Pointers Program development Examples of programs Arduino programs Summary Problems 13 Input/output systems 13.1 13.2 13.3 13.4 13.5 13.6 Chapter objectives Interfacing Input/output addressing Interface requirements Peripheral interface adapters Serial communications interface Examples of interfacing Summary Problems 14 Programmable logic controllers 14.1 14.2 14.3 14.4 14.5 14.6 14.7 14.8 14.9 14.10 14.11 14.12 Chapter objectives Programmable logic controller Basic PLC structure Input/output processing Ladder programming Instruction lists Latching and internal relays Sequencing Timers and counters Shift registers Master and jump controls Data handling Analogue input/output Summary Problems 15 Communication systems Chapter objectives Digital communications Centralised, hierarchical and distributed control 15.3 Networks 15.4 Protocols 15.1 15.2 F01 Mechatronics 50977 Contents.indd 336 340 342 343 345 348 352 352 354 354 354 355 357 364 369 372 380 380 15.5 Open Systems Interconnection communication model 15.6 Serial communication interfaces 15.7 Parallel communication interfaces 15.8 Wireless communications Summary Problems 16 Fault finding 16.1 16.2 16.3 16.4 16.5 16.6 16.7 Chapter objectives Fault-detection techniques Watchdog timer Parity and error coding checks Common hardware faults Microprocessor systems Evaluation and simulation PLC systems Summary Problems 415 418 427 430 431 432 433 433 433 434 435 437 438 441 442 445 445 382 382 382 382 386 387 391 394 396 397 400 401 402 404 406 407 V System models 447 17 Basic system models 449 17.1 17.2 17.3 17.4 17.5 18 System models 409 409 409 409 412 414 Chapter objectives Mathematical models Mechanical system building blocks Electrical system building blocks Fluid system building blocks Thermal system building blocks Summary Problems 18.1 18.2 18.3 18.4 18.5 Chapter objectives Engineering systems Rotational–translational systems Electromechanical systems Linearity Hydraulic–mechanical systems Summary Problems 449 449 450 458 462 469 472 473 475 475 475 475 476 479 481 484 484 30/08/2018 07:09 www.ebookslides.com viii CONTENTS 19 Dynamic responses of systems 19.1 19.2 19.3 19.4 19.5 19.6 Chapter objectives Modelling dynamic systems Terminology First-order systems Second-order systems Performance measures for second-order systems System identification Summary Problems 20 System transfer functions 20.1 20.2 20.3 20.4 20.5 20.6 Chapter objectives The transfer function First-order systems Second-order systems Systems in series Systems with feedback loops Effect of pole location on transient response Summary Problems 21 Frequency response 21.1 21.2 21.3 21.4 21.5 21.6 Chapter objectives Sinusoidal input Phasors Frequency response Bode plots Performance specifications Stability Summary Problems 22 Closed-loop controllers 22.1 22.2 22.3 22.4 22.5 22.6 22.7 485 Chapter objectives Control processes Two-step or on/off mode Proportional mode of control Integral mode of control Derivative mode of control PID controller Digital control systems F01 Mechatronics 50977 Contents.indd 485 485 486 488 494 501 504 505 506 509 509 509 512 514 516 517 519 522 522 524 524 524 525 527 530 539 541 543 544 22.8 Controller tuning 22.9 Velocity control 22.10 Adaptive control Summary Problems 23 Artificial intelligence Chapter objectives 23.1 What is meant by artificial intelligence? 23.2 Perception and cognition 23.3 Fuzzy logic Summary Problems 571 571 571 572 575 585 586 VI Conclusion 587 24 Mechatronic systems 589 Chapter objectives 24.1 Mechatronic designs 24.2 Robotics 24.3 Case studies Summary Problems Research assignments Design assignments Appendices A The Laplace transform A.1 A.2 A.3 A.4 546 546 546 548 550 552 555 557 559 564 566 567 569 569 The Laplace transform Unit steps and impulses Standard Laplace transforms The inverse transform Problems B Number systems B.1 B.2 B.3 B.4 Number systems Binary mathematics Floating numbers Gray code Problems 589 589 600 606 625 625 625 625 627 629 629 630 632 636 638 639 639 640 643 643 644 30/08/2018 07:09 www.ebookslides.com ix CONTENTS C Boolean algebra C.1 Laws of Boolean algebra C.2 De Morgan’s laws C.3 Boolean function generation from truth tables F01 Mechatronics 50977 Contents.indd 645 645 646 647 C.4 Karnaugh maps Problems 649 652 Answers Index 654 669 30/08/2018 07:09 ... in engineering technology in which there is a co-ordinated, and concurrently developed, integration of mechanical engineering with electronics and intelligent computer control in the design and. .. together of a number of technologies: mechanical engineering, electronic engineering, electrical engineering, computer technology and control engineering Mechatronics provides an opportunity to... robots, machine tools, washing machines, cameras and very many other machines, such an integrated and interdisciplinary approach to engineering design is increasingly being adopted The integration