Control of Mechatronic Systems

Model-Driven Design and Implementation Guidelines

Patrick O. J. Kaltjob

• Publisher: Wiley
• Year: 2020
• ISBN:
  9781119505754
• Edition: 1
• Topic: Technology & Engineering
• Subtopic: Mechanical Engineering
• Index: Technology & Engineering

A practical methodology for designing integrated automation control for systems and processes

Implementing digital control within mechanical-electronic (mechatronic) systems is essential to respond to the growing demand for high-efficiency machines and processes. In practice, the most efficient digital control often integrates time-driven and event-driven characteristics within a single control scheme. However, most of the current engineering literature on the design of digital control systems presents discrete-time systems and discrete-event systems separately. Control Of Mechatronic Systems: Model-Driven Design And Implementation Guidelines unites the two systems, revisiting the concept of automated control by presenting a unique practical methodology for whole-system integration. With its innovative hybrid approach to the modeling, analysis, and design of control systems, this text provides material for mechatronic engineering and process automation courses, as well as for self-study across engineering disciplines. Real-life design problems and automation case studies help readers transfer theory to practice, whether they are building single machines or large-scale industrial systems.

• Presents a novel approach to the integration of discrete-time and discrete-event systems within mechatronic systems and industrial processes
• Offers user-friendly self-study units, with worked examples and numerous real-world exercises in each chapter
• Covers a range of engineering disciplines and applies to small- and large-scale systems, for broad appeal in research and practice
• Provides a firm theoretical foundation allowing readers to comprehend the underlying technologies of mechatronic systems and processes

Control Of Mechatronic Systems is an important text for advanced students and professionals of all levels engaged in a broad range of engineering disciplines.

1
Introduction to the Control of Mechatronic Systems

1.1 Introduction

The rapid expansion of automated electrically-driven systems (e.g. electromechanical machines) is related to the development of digital control strategies in order to enhance their performance and extend their functionality while significantly reducing their operating cost and complexity. However, those digital control strategies are dependent on the performance of the control instrumentation related to measurement, signal conditioning, actuating, and digital control technologies. Recent technology advancements offer a plethora of control systems instrumentation, each with design-specific requirements and compliance constraints. Hence, in addition to system modeling, the design of digital control strategies has to consider: (i) the selection of control instrumentation in accordance with performance objectives; and (ii) the integration of the control systems instrumentation and process equipment with respect to operating constraints.

Consequently, it is suitable to lay out a generic design procedure for digital control systems, especially in: (i) controlling electrically-driven systems; (ii) sizing and selecting control instrumentation related to information processing and computing, electrically-driven actuation, process sensing and data acquisition; (iii) integrating those control instrumentation with respect to controlled system performance objectives and operating constraints; and (iv) integrating multifunctional control applications.

In this chapter, the definition and classification of electrically-driven systems and technical processes are presented first. Then the functional relationship between electromechanical machine control and control within interconnected and synchronized electromechanical systems is outlined. Various components of control systems instrumentation are described along with their design requirements. Furthermore, major steps of control system migration projects are presented with some illustrative examples of industrial process control. Finally, key project management steps and the associated subsequent design documents are listed.

1.2 Description of Mechatronic Systems

Mechatronic systems are either electrically-driven products or technical processes. Electrically-driven products are machines transforming current, voltage, or other electrical power into mechanical, fluidic, pneumatic, hydraulic, thermal, or chemical power. Hence, those systems can be classified according to their functional objectives either as: (i) specialized machines performing specific operations; or (ii) multipurpose and adjustable machines. Control systems are a set of technologies enabling algorithmic computing or signal processing devices to use signals emitted from analog or digital detecting, sensing, and communicating devices in order to perform automatic operations of systems or process actuation. Such systems are expected to perform them routinely and independently of human intervention with a performance superior to manual operation.

Thus, control systems aim to provide the necessary input signals to achieve the desired patterns of variations of specific process variables. Therefore, the functions of control systems are embedded in electromechanical systems (machine or product control).

Example 1.1

Figure 1.1 shows a typical 3D printing robot for customized cooking with speed- and temperature-controlled system which could be combined with monitoring indicators for cooking time and cooking stage, as well as a control panel allowing the selection of the final mixing of the product and cooking program. This system would require:

1. the angular position control of a pressure valve delivering semi-liquefied food (paste), the x-y axis position control of the carriage driving the extruder head (nozzle) made of two motors with a screw mechanism, the table angular speed and the z-axis position control;
2. the heater temperature control (nozzle level);
3. the remote pressure and force control for the valve in charge of injecting pressured food paste feed based on environmental (e.g. space mission) and biological conditions (e.g. lower gravity forces); and
4. the logic control for the discrete selection of ingredients.

Figure 1.1 Customized 3D food printer.

Such control design combination enhances the product or machine functionality while reducing operating and maintenance costs. This is done by integrating data processing and computing operations within a field device or machine (e.g. washing machine, navigation systems etc.). Among the commonly encountered automated machines or products are those with: (i) embedded control functions; (ii) dedicated control functions; or (iii) a control function limited to a couple of sensors and actuators involved.

A technical process is the sum of all interacting machines within that process transforming and/or storing material, energy, or information. Such technical processes can be classified according to their operational objectives as follows:

1. Transportation-related processes, such as material handling processes, energy flow processes, and information transmission processes.
2. Transformation-related processes, such as chemical processes, manufacturing processes, power generation, and storage processes.

Technical processes can be characterized according to functional objectives, such as:

1. Processes characterized by a continuous flow of material or energy (e.g. cement drying process, electric ...