Basic mechatronics

Monday, May 1, 2023 Basic Mechatronics 1

BASIC MECHATRONICS


Objectives of this course• To study the definition and elements of mechatronics

system.• To learn how to apply the principles of mechatronics

and automation for the development of systems.• To study the PLC, Pneumatic, Sensors & Modular

Production System (MPS).• To learn the Automation technology and industrial

automation/robotics as applications of Mechatronics in manufacturing system.


What is “Mechatronics” ?• Mechatronics is a concept of Japanese origin (1970’s)

and can be defined as the application of electronics and computer technology to control the motions of mechanical systems.

Mechatronics

Mechanism Electronics


What is “Mechatronics” ?• It is a multi-disciplinary approach

to product and manufacturing system design.

• It involves application of electrical, mechanical, control and computer engineering to develop products, processes and systems with greater flexibility, ease in redesign and ability of reprogramming.

• It concurrently includes all these disciplines.


Mechatronics Definition• “The name [mechatronics] was coined by Ko Kikuchi, now president of

Yasakawa Electric Co., Chiyoda-Ku, Tokyo.”• R. Comerford, “Mecha … what?” IEEE Spectrum, 31(8), 46-49, 1994.

• “Integration of electronics, control engineering, and mechanical engineering.”

• W. Bolton, Mechatronics: Electronic Control Systems in Mechanical Engineering, Longman, 1995.

• “Application of complex decision making to the operation of physical systems.”

• D. M. Auslander and C. J. Kempf, Mechatronics: Mechanical System Interfacing,Prentice-Hall, 1996.

• “Methodology used for the optimal design of electromechanical products.”• D. Shetty and R. A Kolk, Mechatronics System Design, PWS Pub. Co., 1997.


Introduction to Mechatronics• Mechatronics can also be termed as replacement of mechanics

with electronics or enhance mechanics with electronics. • For example, in modern automobiles, mechanical fuel injection

systems are now replaced with electronic fuel injection systems.

• This replacement made the automobiles more efficient and less pollutant.

• With the help of microelectronics and sensor technology, mechatronics systems are providing high levels of precision and reliability.


Introduction to Mechatronics• By employment of reprogrammable microcontrollers or

PLC, it is now easy to add new functions and capabilities to a product or a system.

• Today’s domestic washing machines are “intelligent” and four-wheel passenger automobiles are equipped with safety installations such as air-bags, parking (proximity) sensors, antitheft electronic keys etc.


Importance of Mechatronics in automation• Today’s customers are demanding more variety and

higher levels of flexibility in the products. • Due to these demands and competition in the market,

manufacturers launch new/modified products to survive. • It is reducing the product life as well as lead-time to

manufacture a product. • It is therefore essential to automate the manufacturing

and assembly operations of a product. • There are various activities involved in the product

manufacturing process.


Importance of Mechatronics in automation


What CAD/CAM/CAE• CAD: Computer-Aided

Design• CAM: Computer-Aided

Manufacturing• CAE: Computer-Aided

Engineering


CAD/CAM/CAE software• CAD – 2D drafting

• AutoCAD, TwinCAD, etc.• CAD – Solid modeling

• Solid Edge, SolidWorks, Mechanical Desktop(MDT), etc.• CAM

• SOLIDCAM, SURFCAM, MasterCAM, SmartCAM, etc.• CAE

• ANSYS, ABAQUS, NASTRAN, ADAMS, MOLDFLOW, etc


Microprocessor• CPU for

Computers• No RAM, ROM,

I/O on CPU chip itself

• Example： Intel’s x86, Motorola’s 680x0

CPUGeneral-Purpose Micro-processor

RAM ROM I/O Port

TimerSerial COM Port

Data Bus

Address Bus

General-Purpose Microprocessor System

Many chips on mother’s board


Microcontroller • A smaller

computer• On-chip RAM,

ROM, I/O ports...

• Example：Motorola’s 6811, Intel’s 8051, Zilog’s Z8 and PIC 16X

RAM ROM

I/O Port

TimerSerial COM Port

Microcontroller

CPU

A single chip


Microprocessor vs. MicrocontrollerMicroprocessor • CPU is stand-alone, RAM,

ROM, I/O, timer are separate

• designer can decide on the amount of ROM, RAM and I/O ports.

• expansive• versatility • general-purpose

• Microcontroller• CPU, RAM, ROM, I/O and timer

are all on a single chip• fix amount of on-chip ROM,

RAM, I/O ports• for applications in which cost,

power and space are critical• single-purpose


PC-based Measurement and Control

PC Board

GPIB Serial/paralell CAN BUS

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Sensors and Actuators• Sensor A device that converts an environmental condition into an

electrical signal.• Actuator A device that converts a control signal (usually electrical) into mechanical action (motion).

(Taken together, sensors, actuators, controllers, and power supply form

the basic elements of a control system.)


Actuators-Motors


The Following Special Formulation is Offered Mechatronics studies synergistic fusion of precise

• mechatronical units,• electronic, • electro technical and computer components

for the purpose of designing and manufacturing qualitatively new

• modules, • systems, • machines and complexes of machines

with intellectual control of their functional movements


Examples of Mechatronic Systems

clothes washer

computer disk drive


Mechatronics system


Levels of Mechatronic Systems’ Integration

• conveyors, • rotary tables,• auxiliary manipulators

The First Level



• operated power machines (turbines and generators),

• machine tools and industrial robots with numerical program management

The Second Level



Synthesis of new precise, information and measuring high technologies gives a basis for designing and producing intellectual mechatronic modules and systems.

The Third Level


Mechatronics system• A Mechatronics system

integrates various technologies involving

• Sensors & Measurement systems,

• Drives & Actuation systems (Mechanical /Pneumatics /Hydraulics),

• Controlling system (microprocessor / microcontroller /PLC) and software engineering.


Disciplinary Foundations of Mechatronics• Mechanical Engineering• Electrical Engineering• Electronics Engineering• Computer Engineering• Information & Technology Engineering


Mechatronics Systems in our daily life

MEMS

Tools

Computers Cars

Consumer Electronics

Stealth Bomber

High Speed Trains


Mechatronics Systems in Manufacturing Applications

•Desktop sized Factory •Build small parts with a small factory •Greatly reduces space, energy, and materials

Micro Factory Micro Factory Drilling Unit


Mechatronics Systems in Manufacturing ApplicationsCNC Bending•Fully automated bending: load sheet metal and the finished bent parts come out•Can bend complex shapes


Mechatronics Systems in Transportation ApplicationsTypical Applications •Brake-By-Wire system •Steer-By-Wire•Integrated vehicle dynamics •Camless engines•Integrated starter alternator

AutomobilesOEM Driven•Reliability •Reduced weight •Fuel economy •Manufacturing flexibility•Design freedom •Advanced safety features •Cost


•Train Position and Velocity constantly monitored from main command center. •Error margin in scheduling no more than 30 seconds•Fastest trains use magnetic levitation

High Speed Trains

JR-MaglevTop Speed: 574 km/h (357 mph)Country: Japan

TransrapidTop Speed: 550 km/h (340 mph)Country: German

Magnetic Levitation

Transportation Applications


AdvantagesSimple and intuitive personal transportation device

Systems Uses•Tilt and pressure sensors •Microcontroller•Motors•Onboard power source

Segway

Transportation Applications


System Can•Carry 340 lb•Run 4 mph•Climb, run, and walk•Move over rough terrain

BigDog

AdvantagesRobot with rough-terrain mobility that could carry equipment to remote location.

Smart Robotics Application


Robots can vacuum floors and clean gutters so you don't have to.

Cleans Gutter

Vacuum Floors

Smart Robotics Application


Prosthetics

Arms, Legs, and other body parts can be replaced with electromechanical ones.

Medical Applications


Used by patients with slow or erratic heart rates. The pacemaker will set a normal heart rate when it sees an irregular heart rhythm.

Monitors the heart. If heart fibrillates or stops completely it will shock the heart at high voltage to restore a normal heart rhythm.

Pace Maker

Implantable Defibrillation

Medical Applications


•Advanced technology is making our soldiers safer.•Some planes can now be flown remotely.

Unmanned Aerial Vehicle

Stealth Bomber

Defense Applications


System Uses•Proximity sensors •Control circuitry •Electromechanical valves•Independent power source

Advantages•Reduces spread of germs by making device hands free•Reduces wasted water by automatically turning off when not in use

Sanitation Applications


Advantages•Reduces spread of germs by making device hands free•Reduces wasted materials by controlling how much is dispensed

Systems Uses•Motion sensors •Control circuitry •Electromechanical actuators •Independent power source

Soap Dispenser

Paper Towel Dispenser

Sanitation Applications


Advantages•Automatically changes cushioning in shoe for different running styles and conditions for improved comfort

Running Shoes

Sports Applications


Smoke Detector System

Smart Home Applications


Introduction to PLC

WHAT IS A CONTROL ??Control means to make an out put ON or OFF by help of Controlling Devices like simple toggle switch to a complex system with components such as relays, timers, and switches.


TYPES OF CONTROL• 1) On-Off control,• 2) Sequential control, • 3) Feedback control, and • 4) Motion control.


EXAMPLE OF AN UNCONTROLLED CIRCUIT.


A CONTROLLED CIRCUIT


MANUAL CONTROL AND AUTOMATIC CONTROL• Control circuits may require • Manual control• Automatic control• or • Combination of both.

EXAMPLE OF MANUAL CONTROLManual Control circuits use components that require human interaction in order to operate.

ACsource

Toggle switch

EXAMPLE OF MANUAL CONTROLAfter the toggle switch is made on manually the bulb gets ON.

ACsource

Toggle switch

EXAMPLE OF AUTOMATIC CONTROLAutomatic control circuits can operate themselves without the need for human interaction.

ACsource

Float switch

EXAMPLE OF AUTOMATIC CONTROLFloat Switch has been operated by a floating arrangement Automatically.So no human interaction is required for this control

ACsource

Float switch


AN EXAMPLE OF ONE LINE DIAGRAM


EVOLUTION OF PLC• MANUAL CONTROL• HARDWIRE LOGIC(RELAYS,CONTACTORS,TIMERS)• LOGIC GATES• PLC


WHAT IS A PLC ??• A Programmable Logic Controller (PLC for short) is

simply a special computer device used for industrial control systems.

• They are used in many industries such as oil refineries, manufacturing lines, conveyor systems and so on.

• Where ever there is a need to control devices, the PLC provides a flexible way to "software" the components together.


BASICS OF A PLC.


DETAILS OF PLC ??

REQUIREMENT OF PLC OPERATIONThe student needs:• PC ( Personal Computer ) • PLC’s software ( Simatic Manager) to write the

programme in a programming language(LAD). • A physical PLC Unit (With a demo kit) to test the

output of the programme written on above language.

• Or a Simulator software to test the output of the programme without the presence of a physical PLC Unit.

PROGRAMMING LANGUAGES• LADDER LOGIC

• FBD LOGIC (FUNCTIONAL BLOCK DIAGRAM)

• STL LOGIC(STATEMENT LIST)


A PHYSICAL CIRCUIT FOR MAKING A LAMP ON BY A SWITCH.

HOT line NEUTRAL line


LADDER PROGRAMMING


FBD PROGRAMMING


STL PROGRAMMING


EXAMPLES OF AUTOMATED PLANTS






Sensors & Application


Introduction• Measurement is an important subsystem of a

mechatronics system. • Its main function is to collect the information on system

status and to feed it to the micro-processor(s) for controlling the whole system.

• Measurement system comprises of sensors, transducers and signal processing devices.


Sensor• It is defined as an element which produces signal

relating to the quantity being measured. According to the Instrument Society of America, sensor can be defined as “A device which provides a usable output in response to a specified measurand.” Here, the output is usually an ‘electrical quantity’ and measurand is a ‘physical quantity, property or condition which is to be measured’. Thus in the case of, say, a variable inductance displacement element, the quantity being measured is displacement and the sensor transforms an input of displacement into a change in inductance.


Transducer• It is defined as an element when subjected to some physical change

experiences a related change or an element which converts a specified measurand into a usable output by using a transduction principle. It can also be defined as a device that converts a signal from one form of energy to another form. A wire of Constantan alloy (copper-nickel 55-45% alloy) can be called as a sensor because variation in mechanical displacement (tension or compression) can be sensed as change in electric resistance. This wire becomes a transducer with appropriate electrodes and input-output mechanism attached to it. Thus we can say that ‘sensors are transducers’.

• Sensor specifications inform the user to the about deviations from the ideal behavior of the sensors. Following are the various specifications of a sensor/transducer system.


Sensors used in our MPS are follows• Micro Limit Switch, • Features: Short Hinge Roller

Lever Actuator, 1NO+1NC Contact Configuration, 3 Terminals. Designed to control the movement of a mechanical part. Typically utilized in industrial control applications to automatically monitor and indicate whether the travel limits of a particular device have been exceeded. High precision mechanism design offering acute operation and long life.


Sensors used in our MPS are follows• Magnetic reed proximity

sensor, the reed switch is an electrical switch operated by an applied magnetic field. It was invented at Bell Telephone Laboratories in 1936 by W. B. Ellwood. It consists of a pair of contacts on ferrous metal reeds in a hermetically sealed glass envelope. The contacts may be normally open, closing when a magnetic field is present, or normally closed and opening when a magnetic field is applied.


Optical proximity sensors• Optical proximity sensors use optical and electronic means for

object detection.• Photo emitting devices such as Light emitting diodes (LEDs) and

photosensitive devices such as photo diodes and photo transistors are used in combination to work as proximity sensing devices.

• Red or infrared light is used. Semiconductor light-emitting diodes (LEDs) are particularly reliable sources of red or infrared light.

• LED are small and rugged, have a long service life and can be simply modulated.

• Photodiodes or phototransistors are used as a receiver.• Red light has the advantage that the light beam can be seen during

adjustment of the optical axes of the proximity switch.


Working• The basic idea is to make

use of IR LED to send the infrared waves to objects.

• Another IR phototransistor of same type is to be used to detect the reflected wave from the object.


Working• When IR receiver is subjected to infrared light, a

voltage difference is produced across the leads.• Less voltage which is produced can be hardly

detected and hence operational amplifiers(Op-amps)are used to detect the low voltages accurately.


5mm Infrared LED• An IR LED, also known as IR

transmitter, is a special purpose LED that transmits infrared. Such LEDs are usually made of gallium arsenide or aluminium gallium arsenide.

• The device is specially matched with phototransistor, photodiode and infrared receiver module.

• The infrared emitting diode is a high intensity diode, molded blue transparent plastic package.


Photodiode (IR Receiver)• PT333-3C is a high speed

and high sensitive photodiode molded in a standard 5mm package.


Different types of optical proximity switch• Three different types of optical proximity switch are

differentiated:One-way light barrier

Reflective light barrier

Diffuse reflective optical sensor


One-way light barrier• The one-way light barrier

has spatially separate transmitter and receiver units.

• The parts are mounted in such a way that the transmitter beam is directed at the receiver.

• The output is switched if the beam is interrupted.


Reflective light barrier• In the reflective light barrier,

the transmitter and receiver are mounted together in one housing.

• The reflector is mounted in such a way that the light beam transmitted by the transmitter is practically completely reflected to the receiver.

• The output is switched if the beam is interrupted.


Diffuse reflective optical sensor• In the diffuse reflective optical sensor,

the transmitter and receiver are mounted together in one unit.

• If the light hits a reflective object, it is redirected to the receiver and causes the output of the sensor to switch.

• Because of the functional principle, the diffuse reflective optical sensor can only be used if the material or machine part to be detected is highly reflective (for example polished metal surfaces, bright paint).


Symbol• Symbol for proximity• Symbol for LED• +ve terminal• -ve terminal• Output terminal


Basic pneumatics training


Section details• Part A: Course

• The course provides the necessary information on the subject concerned using both examples and exercises, and is to be worked through in sequence. Subjects which are dealt with in greater depth in the Theory section are marked in the text.

• Part B: Theory • This section contains detailed information on fundamentals.

Topics are set out in a logical manner. The student can either work through this section chapter by chapter or use it for reference purposes.


Training aims• Structure, function and application

of single-acting and double-acting cylinders

• Calculating basic parameters• Direct and indirect actuation• Application and function of 3/2 and

5/2-way valves• Methods of actuation of directional

control valves• Analysing circuits• Options for pressure measurement• Pressure-dependent control systems

• Distinguishing flow control methods and using them as intended

• Explaining and building latching circuits

• Logic operations: explaining and implementing AND/OR/NOT operations

• Combining logic operations• Function and application of limit

switches• Time delay valves• Realising oscillating movement


Introduction to pneumatics• During the few decades various automation techniques

has been introduced in the field of manufacturing in order to enhance the overall industrial productivity.

• Among the various technologies that are playing important role in rapid growth of Indian industries, fluid power is unique.

• During past decade number of applications have been developed based on Pneumatics.


Pneumatics - Definition• The study of pneumatics deals with system

operation with air or gaseous medium to impart power or to control power.

• The term pneumatics is derived from the Greek word pneuma, meaning wind or breath.

• Pneumatic power is the power that is transmitted by pressurized/compressed air.

Normal Air Compressor Compressed Air

Control valve Actuator

A simple pneumatic system


Composition of Atmospheric air• Dry air at sea level comprises 78.03%

nitrogen, 20.99% oxygen, 0.98% argon by volume.

• It also contains traces of carbon dioxide, hydrogen, neon, helium, krypton and xenon.

• Apart from gases, atmospheric air holds many harmful impurities like dust, etc.

• Air has a mass & exert pressure on the surface of the earth.

• Atmospheric pressure at normal sea level is 1.013bar.


Air pressure

• Force [F] is applied to the air enclosed in a chamber through a piston of area [A].

• The enclosed air is compressed and its pressure [P] raised in directly proportional to the applied force and inverse proportional to the area of the piston.

• P=F/A

F


Unit of pressure• In SI system unit of pressure is Pascal (Pa), &

1 Pa is constant pressure acting on surface area of 1 square meter with a perpendicular force of 1 Newton.

• 1Pa = 1N/m^2• For industrial pneumatic purpose, Pascal is to

small unit for use in measurement & hence a more practical unit, called ‘bar’ is used.

• 100,000 Pa = 1 bar• 14.5 psi (Pound per inch) = 1 bar


Pneumatic applicationsSome industrial applications employing pneumatics are listed below:

• General methods of material handling:

• – Clamping • – Shifting • – Positioning • – Orienting • – Branching of material flow

• General applications: • – Packaging • – Filling • – Metering • – Locking • – Driving of axes • – Door control • – Transfer of materials • – Turning and inverting of

parts • – Sorting of parts • – Stacking of components • – Stamping and embossing of

components


Pneumatic applications

Points switch for two conveyor belts Pneumatic cutter


Standardization• For a uniform definition & standardization of

pneumatic components were initiated by German organization like VDI & VDMA.

• This led to DIN & CETOP & later to DIN ISO standards & recommendations for a uniform consistent terminology in pneumatics.

• System engineer must draw pneumatic circuit that installation engineer & maintenance person can read & understand easily. Therefore standardization was required.


Standardization• CETOP : Comité Européen des Transmissions

Oléohydrauliques et Pneumatiques is a federation of European manufacturing, which is involved, since 1962.

• DIN : Deutsches Institute fur Normung E.V.• VDI : Verin Deutscher Ingenieure (Association of

German Engineers)• VDMA : Verband Deutscher Maschinen und Anlagenbau

(Association of Mechanical Engineers)


Some pneumatic standards• ISO 1219-1 2006 : fluid power system &

component – Graphic symbols & circuit diagram.

• ISO 5599 : Port marking of pneumatic direction control valve.

• ISO 6432, 6431 : Mounting dimension of pneumatic cylinders.

• CETOP RP41 : Hydraulic & Pneumatic system circuit diagram.

• And many more…


Compressed Air Generation &

Contamination Control


A typical pneumatic system


Air generation and distribution

• The generation of compressed air starts with compression.

• The compressed air flows through an entire series of components before reaching the consuming device.

• The equipment to be considered in the generation and preparation of air include :

Inlet filter Air compressor Air reservoir Air dryer Air filter with water separator Pressure regulator Air lubricator as required Drainage points


Intake filter• It is used to clean & filter the air used for systems.• Before the surrounding air enters the compressor, it

must pass through a filter to remove most of the dirt & other solid contaminants.

• These filters can be of dry or wet type depending on the compressor manufacturer & the application.


Air compressors• A compressor is the most common industrial energy

supply unit that convert mechanical energy into fluid energy.

• It is design to take in air at atmospheric pressure and deliver the received air to a closed system with a certain volumetric flow rate, at a higher pressure.


Reciprocating piston compressors• A piston compresses the air drawn in via an inlet valve.

The air is passed on via an outlet valve. • Reciprocating compressors are very common and

provide a wide range of pressures and delivery rates. • For higher pressures multistage compression is used

with inter-cooling between each stage of compression.


Reciprocating piston compressors

• A reciprocating compressor consist of the crankshaft by a connecting rod.

• Crankshaft is externally rotate by a electric motor.

• Crankshaft & connecting rod convert rotary motion into reciprocating motion.


Flow compressor

• These are particularly suitable for large delivery quantities.

• Flow compressors are made in axial or radial form. The air is made to flow by means of one or several turbine wheels.

• The kinetic energy is converted into pressure energy.

• In the case of an axial compressor, the air is accelerated in the axial direction of flow by means of blades.


Reservoirs

• A reservoir is configured downstream of a compressor to stabilise compressed air.

• A reservoir compensates the pressure fluctuations when the compressed air is taken from the system.

• If the pressure in the reservoir drops below a certain value, the compressor will compensate until the set higher value is reached again.

• This has the advantage that the compressor does not need to operate continuously.


Reservoirs


Air dryers• The most common type of dryer today is the

refrigeration dryer. • With refrigerated drying, the compressed air is passed

through a heat exchanger system through which a refrigerant flows.

• The aim is to reduce the temperature of the air to a dew point which ensures that the water in the air condenses and drops out in the quantity required.



Compressed air filter • The selection of the correct filter plays an important role in

determining the quality and performance of the working system which is to be supplied with compressed air.

• One characteristic of compressed-air filters is the pore size. • The pore size of the filter element indicates the minimum

particle size which can be filtered out of the compressed air.


Compressed air filter


Lubricator• As a rule the compressed air which is generated should be dry, i.e. free of

oil. • For some components lubricated air is damaging, for others, it is

undesirable, but for power components it may in certain cases be necessary. • Lubrication of the compressed air should therefore always be limited to the

plant sections which require lubrication. • For this purpose, lubricators are fitted to feed the compressed air with

specially selected oils. • Oils which are introduced into the air from the compressor are suitable for

the lubrication of control system components.



Service unit• The individual functions of compressed air preparation,

i.e. filtering, lubricating and regulating , can be fulfilled by individual components.

• These functions have often been combined into one unit, i.e. the service unit or FLR.

• Service units are connected upstream of all pneumatic systems.


Service unitAir filter

Pressure control valve

Pressure gauge


Service unit



Actuators


Actuators and output devices• An actuator is an output device for the conversion of supply

energy into useful work. • The output signal is controlled by the control system, and the

actuator responds to the control signals via the control element. • Other types of output devices are used to indicate the status of

the control system or actuators, e.g. a pneumatically actuated visual display.


Actuators and output devices• The pneumatic actuator can be described under two

groups, linear and rotary :• Linear motion

• Single-acting cylinders • Double-acting cylinders

• Rotary motion • Air motor • Semi-Rotary actuator


Single-acting cylinders• With single-acting cylinders compressed air is applied

on only one side of the piston face. The other side is open to atmosphere.

• The cylinder can produce work in only one direction. The return movement of the piston is effected by a built-in spring or by the application of an external force.

• The spring force of the built-in spring is designed to return the piston to its start position with a reasonably high speed under no load conditions.


Single-acting cylinders

Spring to push Spring to pull


Plunger type single acting cylinder

• In the case of plunger cylinders, the piston and rod form a single component.

• Due to the design of the cylinder, the return stroke can only be effected by external forces.

• The cylinders can therefore generally be installed only vertically.


Double-acting cylinders• The construction principle of a double-acting cylinder is

similar to that of the single-acting cylinder. • But no return spring, and the two ports are used

alternatively as supply and exhaust ports. • The double-acting cylinder has the advantage that the

cylinder is able to carry out work in both directions of motion.

• The force transferred by the piston rod is somewhat greater for the forward stroke than for the return stroke as the effective piston surface is reduced on the piston rod side by the cross-sectional area of the piston rod.


Double-acting cylinders


Double-acting cylinder with cushioning• If large masses are moved by a cylinder, cushioning is

used in the end positions to prevent sudden damaging impacts. Before reaching the end position, a cushioning piston interrupts the direct flow path of the air to the outside.

• Instead a very small and often adjustable exhaust aperture is open.

• For the last part of the stroke the cylinder speed is progressively reduced. If the passage adjustment is too small, the cylinder may not reach the end position due to the blockage of air.


Double-acting cylinder with cushioning


Tandem double-acting cylinder• The tandem cylinder incorporates the features of two

double-acting cylinders which have been joined to form a single unit. By this arrangement and with the simultaneous loading of both pistons, the force on the piston rod is almost doubled.

• This design is suitable for such applications where a large force is required but the cylinder diameter is restricted.


Tandem double-acting cylinder


Cylinders with through piston rod• This cylinder has a piston rod on both sides, which is a

through piston rod. The guide of the piston rod is better, as there are two bearing points. The force is identical in both directions of movement.

• The through piston rod can be hollow, in which case it can be used to conduct various media, such as compressed air. A vacuum connection is also possible.


Cylinders with through piston rod


Multi-position cylinders• The multi-position cylinder consists of two or several

double-acting cylinders, which are interconnected. • The individual cylinders advance when pressure is

applied. In the case of two cylinders with different stroke lengths, four positions are obtained.


Multi-position cylinders


Multi-position cylinders


Rotary cylinders• With this design of double-acting cylinder, the piston

rod has a geartooth profile. • The piston rod drives a gear wheel, and a rotary

movement results from a linear movement. • The range of rotation varies from 45o, 90o, 180o,

270oto 360o. • The torque is dependent on pressure, piston surface

and gear ratio; values of roughly up to 150 Nm are possible.


Rotary cylinders


Diaphragm cylinder• This is the simplest form of single acting cylinder. In diaphragm cylinder ,

piston is replaced by a diaphragm is replaced by a diaphragm of hard rubber, plastic or metal clamped between the two halves of a metal casing expanded to form a wide, flat enclosure.

• The operating stem which takes place of the piston rod in diaphragm cylinder can also be designed as a surface element so as to act directly as a clamping surface for example.

• Only short operating strokes can be executed by a diaphragm cylinder, up to a maximum of 50 mm. This makes the diaphragm type of cylinder particularly adaptable to clamping operations.

• Return stroke is accomplished by a spring built into the assembly or by the tension of diaphragm itself in the case of very short stroke.

• Diaphragm cylinders are used for short stoke application like clamping, riveting, lifting, embossing and riveting


Diaphragm cylinder


Cylinder construction • The cylinder consists of a cylinder barrel, bearing and end

cap, piston with seal (double-cup packing), piston rod, bearing bush, scraper ring, connecting parts and seals.

• The cylinder barrel (1)• The end cap (2) • The bearing cap (3) • The piston rod (4)• Sealing ring (5)• Bearing bush (6) • In front of this bearing bush is a scraper ring (7).


Air Motors• Devices which transform pneumatic energy into

mechanical rotary movement with the possibility of continuous motion are known as pneumatic motors.

• The pneumatic motor with unlimited angle of rotation has become one of the most widely used working elements operating on compressed air.

• Pneumatic motors are categorised according to design:• Piston motors • Sliding-vane motors • Gear motors • Turbines (high flow)


Air Motors


Semi rotary actuator

• The limited angle rotary actuator is applied when the shaft has to rotate over a limited angle. The animation shows how this simple actuator works: in this case the shaft can rotate over an angle of about 270 degrees. This type of actuator is, among others, used as a rotator actuator on (small) cranes and excavators .


Semi rotary actuator


Pneumatic grippers• Handling equipment must have grippers for picking up,

moving and releasing the workpiece. Grippers establish either a force-locking or a positive-locking connection with the part.

• All gripper types have a double-acting piston drive and are self-centring.

• Contactless position sensing is possible with proximity sensors. External gripper fingers make the grippers suitable for a wide variety of applications.


Pneumatic grippers• Pneumatic grippers

• a) Radial grippers • b) Parallel grippers • c) 3-point grippers • d) Angle grippers


Vacuum generators• Handling with suction cups is generally a simple, low-

cost and reliable solution. • Suction cups allow the handling of different workpieces

with weights ranging from a few grammas right up to several hundred kilo grammas.

• They come in a wide variety of different shapes, such as universal, flat or bellows suction cups, for example.


Vacuum generators & Sucker




Pneumatic Valves


Pneumatic Valves• Valve is a device which is used to control out put of the

circuit.• The main purpose of a valve in pneumatics or hydraulic

circuit is to control Final output.• Valves are divided into number of groups according to

what they control.


Classification of Valves• Function

• Example: DCV, FCV, PCV.• Design

• Example: Spool valve, poppet valve.• Method of actuation

• Manual, mechanical, pneumatic, electric.• Mounting angle

• Manifold, in line, sub plate.• Application

• Speed control, signal processing, proportional valve.


Functional Classification of Valves• Most commonly used valves are.• Direction control valve (DCV).• Non return valves.• Pressure control valve (PCV).• Flow control valve (FCV).


Direction control valves• Control valve symbols –

• The basic symbol for control valve is a square.• Two or more squares are used.• Each square representing the switching position

provided by the valve.• Two position valve.• Three position valve.


Graphical representation

• Lines in the boxes are used to show flow path with arrow indicating direction of flow.

• The shut off position is indicated by the line drawn at right angle to the horizontal line inside the rectangle.

FLOW

SHUT OFF / NO FLOW


Graphical representation• PIPE CONNECTIONS• The pipe connections i.e. inlet and outlet ports to the

valve are indicated by lines drawn on outside of the box and right angle to the horizontal line .

• The first position from left indicates the rest, initial or neutral position when the valve is not actuated.

• The second position or square from left indicates actuated position.


Graphical representation• PIPE CONNECTIONS• Single position (initial)

• Two position valve

• Three position valve


Graphical representation• PORT & POSITIONS TABLE:• The ports of the valve are show on the outside of the

box.• These are labeled by a number or letter according to its

functions. • For this purpose some standard letters or numbers

with symbols are used which are shown in the following table.


Graphical representation• PORT & POSITIONS TABLE:

Port Alphabetic system

No. sys. Comment

Pressure port P 1 Supply portWorking port A 2 3/2 DC valveWorking ports A, B 4, 2 4/2 or 5/2 DC valveExhaust port R 3 3/2 DC valveExhaust ports R, E,S 3, 5 3/2 DC valvePilot port Z or Y 12 Pilot line (1 2)Pilot port Z 14 Pilot line (1 4)Pilot port Z or Y 10 Pilot line (flow closed)Internal pilot port Pz, Py 81, 91 Auxiliary pilot air


COMMONLY USED DIRECTION CONTROL VALVE.• D.C. valve is used to control or to change the direction

or to start or stop the fluid flow only on the receipt of any signal which may be mechanical, electrical or a fluid pressure pilot signal.

• D.C. valves are described by number of ports and number of positions

• n / n way valve• ( n = 1, 2, 3,……)


COMMONLY USED DIRECTION CONTROL VALVE.

Way Valve Ports Positions

2/2 2 (1 input , 1 output) 2

3/2 3 (1 input, 1 output, 1 exhaust) 2




Ports and positions (ways)


2/2 way valve• 2/2 way Normally closed valve • Initially no flow from1 to 2, switched to flow from 1 to

2. figure indicates 2/2 way valve normally closed and that when activated connects pressure port (1) to the output port (2) and therefore it is used for ON/OFF switch.

1 (P)

2 (A)


2/2 way valve• 2/2 way Normally opened valves • Initially flow from 1 to 2. Switched to no flow from

1to2. figure shows 2/2 way valve normally opened with the pressure port (1) connected to the output port (2) when activated it close both the ports and it is also used for ON/OFF switch.

1 (P)

2 (A)


3/2 way valve• 3/2 way normally closed valve• Initially no flow from 1to 2 but flow from 2 to 3

switched to flow from 1 to 2 and 3 closed.• Figure shows 3/2 way valve normally closed in which

pressure port 1 is off and output port (2) exhausting via exhaust port (3). when it is activated the pressure is applied to the output port directly and the exhaust port will be closed.

2

1 3


3/2 way valve• 3/2 way normally opened valve–• Initially flow from 1 to 2 and 3 closed, switched to flow

from 2 to 3 and no flow from 1. figure indicates 3/2 way valve normally opened in which pressure is connected to the output port and exhaust port is closed. When activated pressure port (1) is off and output port (2) exhaust via exhaust port (3). 2

1 3


4/2 way valve• 4/2 way valve • Initially flow from 1 to 2 and 4 to 3.switched to flow or

from 1 to 4 and from 2 to 3. A 4/2 way valve is shown in figure in which pressure is applied to the output port while the output port exhaust through the exhaust port. When activated the pressure port (1) is connected to the output port (4) while output port (2) exhaust through the exhaust port (3).

4 2

1 3


5/2 way valve• 5/2 way valve• Initially flow from 1 to 2 and flow 4 to 5, 3 closed.

Switched to flow from 1 to 4 and from 2 to 3, 5 closed. Figure indicates 5/2 way valve in which pressure is applied to the output port while output port exhaust through the exhaust port. When activated pressure (1) is connected to the output port (4) exhaust through exhaust port (5) 3 will be closed.

4 2

51

3


Methods of actuation






3/2 way valve

2

1 3

2

1 3

Push button operated spring returned3/2 way normally closed valve

Push button operated spring returned3/2 way normally open valve


3/2 way valve

Internal construction of a 3/2 way normally closed valve


Striking switch

2

1 3striking switch

3/2 way normally closed valve


3/2 way valve

Internal construction of a 3/2 way normally open valve


3/2 way valve

2

1 3

Roller operated spring returned 3/2 way normally closed valve

Roller operated spring returned 3/2 way normally open valve

2

1 3


3/2 way roller operated valve

Internal construction of a roller operated 3/2 way NC valve


3/2 way Idle return roller operated spring returned

2

1 3

Idle return roller operated spring returned

3/2 way normally Closed valve


Pneumatically operated spring returned


3/2 way normally closed valve(3/2 way single pilot)


3/2 way normally open valve(3/2 way single pilot)

2

1 3

2

1 3

12 12



Internal construction of a 3/2 way single pilot valve NC


4/2 BOTH SIDE PILOT OPERATED VALVE

14 12

Pneumatically operated Spring returned 5/2 way valve(5/2 way single pilot)

MEMORY VALVE


4/2 SINGLE SIDE PILOT OPERETED SPRING TO RETURN

14



Pneumatically operated Spring returned

4 2

51

3


14


Push button operated Spring returned

4 2

51

3

striking switch 5/2 way valve


Both pneumatically operated valve• 5/2 way valve

4 2

51

3Pneumatically operated pneumatically return

5/2 way valve(5/2 way double pilot valve / memory valve)

14 12


5/2 way double pilot valve

5/2 way double pilot valve with longitudinal slide


Shutoff valves


Non return valve


Pilot operated check valve


Two pressure valve


Shuttle valve


Flow control valves


Throttle valve


One way flow control valve


Meter in & out control circuits

Meter in control Meter out controlSlow

Normal

Slow

Normal


Pressure control valves• The function of pressure valves, is to influence the

pressure in an overall pneumatic system or in a part of the system. Pressure regulating valves are generally adjustable against spring compression. The symbols are distinguished according to the following types:

• Pressure regulating valve without relief port • Pressure regulating valve with relief port • Pressure sequence valves


Pressure control valves


Auxiliary symbols


Pneumatic control system


Pneumatic control system


Signal flow diagram indicates


Logics• AND logic• OR logic• NOT logic• NAND logic• NOR logic• EX-OR logic


Pneumatic preset counter

The pneumatic preset counter counts pneumatic signals, decrementing from a preset number. When zero is reached, the counter emits a pneumatic output signal.It has 4 ports1 (P) – pressure port / input port2 (A) – output port12 (Z) – pulse counting port10 (Y) – Reset port


Adjustable Pressure Sequence valve


Aluminium profile plate• The aluminium profile plate

forms the basis for all training packages.

• All of the components fit securely and safely into the grooves on the profile plate.

• There are grooves on each side and, if required, both sides can be fitted with components.

• The grooves are compatible with the ITEM profile system.

• Grid dimensions: 50 mm.


Compressor• Oil-lubricated, extremely quiet (45

dB)• Pressure: 800 kPa (8 bar) Pmax• Performance: 50 l/min• Reservoir capacity: 24 l• Noise level: 45 dB/1 m• Pressure regulator valve with

gauge


Electro Pneumatics


Learning objectives


Introduction• Various kind of energy medium can be utilized

within a factory or even within a productionmachine to permit optimum utilization ofdifferent drive and controls.

• Combination of electrical control system andPneumatic power system is named as electroPneumatic system/electro Pneumatics.


Electro Pneumatics• Electro Pneumatic system consist of an electrical

control system operating a Pneumatic power system.• Devices such as solenoid valve, electrical-limit

switches & proximity sensors are used in automaticelectro Pneumatic system.

• The control system has 3 basic divisionscorresponding to its main task:▫ Information gathering [sensors, limit switch, etc.]▫ Processing [relay, logic elements, pressure switch, etc.]▫ Taking action [pneumatics valves]


Integration of technology• The integration of Pneumatic & electrical

technology has played a vital role in theoptimum design & development of a largenumber of industrial production system.

• In complex application, electrical controls areemployed almost exclusively.

• The electrical actuation of Pneumatic valves hascertain advantages over pure Pneumaticcontrols.


Advantages of electro Pneumatics• Speedy signal transmission over great distances.• Signaling components are cheaper.• Less air required in electro Pneumatic system.• Flexibility in development & alteration ofcontrols.• Cost-effective & efficient production system canbe easily designed.• Electrical control devices can be also interfacewith PLC control.


Solenoid valves• As we know Pneumatic valve can be actuatedmanually, pilot or electrically.• In the electrical actuation, the necessary actuationforce is developed electrically to operated a solenoidvalve.• A solenoid valve is a converter that generatespneumatic output in response to a electrical signal.• Solenoid valve are classified into 3 categories:▫ Direct acting valve▫ Pilot operated valve▫ Proportional valve [Advance Electro-Pneumatics]


Fundamental of solenoid valves• When the wire is wound in a form of a longcylinder coil and an iron core is placed in thecenter of that coil and a electric current is passedthrough the coil, a strong magnate field isdeveloped.


Solenoid• A solenoid consist of a coil and moveable ironcore used to convert electrical energy intomechanical energy/movement.• A solenoid design for AC voltage is known as ACsolenoid & solenoid design for DC voltage isknown as DC solenoid.• Both are different in core construction, behaviorduring switching & miscellaneouscharacteristics.


AC & DC currents


DC Solenoids vs AC solenoids• The core of a DC solenoid consist of a solid softiron & the heat losses during the operation of DCsolenoids depend on the coil resistance & thecurrent magnitude.• The operation of solenoids with AC currentintroduces hysteresis & eddy current losses inthe core additionally.• So the armature of the AC solenoid consist oflaminated metal sheets to reduce iron losses.


Behavior of solenoid during switching• When the coil of a DC solenoid is switched on,maximum power is developed before thearmature can pulled in. But, to hold thearmature only little amount of power is need, &rest of the power is given off as heat.• AC solenoids are inductive in nature, thereforewhen an AC solenoid coil is switched on, ahigher initial current is drawn from the supply,& consequently a large force is developed.


Industrial control voltages• In early days the control voltages used inindustries were 230VAC, 110VAC, etc.• The tendency was to reduce the control voltageto a lower level from the operator’s safety pointof view.• The type of supply was also changes from AC toDC due to many advantages of DC supply.• At present , 24V DC is the standard industrialcontrol voltage.


Power supply unit• The signal control section of an electroPneumatic controller is supplied with power viathe electrical mains.


Power supply unit• The transformer reduces the operating voltage. Themains voltage (i. e. 230 V AC) is applied to the input ofthe transformer.• A lower voltage (i. e. 24 V AC) is available at the output.• The rectifier converts the AC voltage into DC voltage.• The capacitor at the rectifier output smooth the voltage.• The voltage regulator at the output of the power supplyunit is required to ensure that the electrical voltageremains constant regardless of the current flowing.


Electro Pneumatics components• 3/2-way single solenoid

valve, spring return


3/2-way single solenoid valve, springreturn


5/2-way solenoid valve, spring return


5/2-way solenoid valve, spring return


5/2-way solenoid valve, both side


Memory function• A memory function ‘remembers’ the state of thelast output even after the input signal (ON)responsible for this output has been removed.• To reset the memory function another input(OFF) need to given.• An electrical latching relay circuit , explained inexample is another example of the memoryfunction.


5/3-way solenoid valve, both side spring


5/3-way solenoid valve, both sidespring


Push button and control switches• Switches are installed in circuits to apply a currentto a load or to interrupt the circuit. These switchesare divided into pushbuttons and control switches.• Control switches are mechanically detente in theselected position. The switch position remainsunchanged until a new switch position is selected.Example: Light switches in the home.• Push button switches only maintain the selectedposition as long as the switch is actuated (pressed).Example: Bell push


Normally open contact


Normally closed contact


Changeover contact


Push button and control switch box


Basic logic Functions• Yes function/Buffer• NOT function• OR function• AND function• NOR function• NAND function• EX-OR function


Relays


Applications of relays• In electro Pneumatic control systems, relays areused for the following functions:▫ Signal multiplication▫ Delaying and conversion of signals▫ Isolation of control circuit from main circuit• In purely electrical controllers, the relay is alsoused for isolation of DC and AC circuits


Limit switches• A limit switch is actuated when a machine partor work-piece is in a certain position. Normally,actuation is effected by a cam.• Limit switches are normally changeovercontacts. They can then be connected – asrequired as a normally open contact, normallyclosed contact or changeover contact.


Limit switches


Proximity switches• In contrast to limit switches, proximity switchesoperated contactless (non-contact switching) andwithout an external mechanical actuating force. As aresult, proximity switches have a long service lifeand high switching reliability. The following types ofproximity switch are differentiated:• Magnetically actuated proximity switch (Reedswitch)• Inductive proximity switch• Capacitive proximity switch• Optical proximity switch


Magnetically actuated proximity switch


Proximity switches• Inductive, optical and capacitive proximityswitches are electronic sensors. They normallyhave three electrical contacts.▫ Contact for supply voltage (24 V)▫ Contact for ground (0 V)▫ Contact for output signal


Inductive proximity sensors


Capacitive proximity sensor


Optical proximity sensor


The MPS – Modular Production System


The MPS – Modular Production System

• The Modular Production System consists of simplified, scaled down versions of actual industrial processes.

• The entire system is broken down into individual modules, usually mounted on trolleys for easy movability.

• Each module is designed to perform a single function, such as Distribution, Pick and Place, Testing, Sorting etc.

• Each module has its own electric / pneumatic supply, control panel, and a PLC for control of its various functions.

Introduction to the MPS


The MPS – Common Components

• Provides the Start / Stop / Reset functions.• Indicators for Start / Reset buttons.• Auto / Manual operation key switch.• Other indications can have different functions.

Control Panel

Touch Panel Buttons

MPS Control Panel



• Sensor outputs, which go to the PLC inputs, are on the rear.

• PLC outputs, which go to solenoid coils are on the front.

Terminal Strip

Top View

Front – PLC Outputs Rear – PLC Inputs



• Each station has an infrared transmitter on the left, and a receiver on the right.

• Distribution station has only receiver, and Sorting station has only transmitter, being the first and last stations.

• The transmitter sends a busy signal to the previous station to signal that the station is not still ready to receive the next work piece.

• When a busy signal is received, the previous station waits till this signal goes away, before passing on the next work piece.

• When stations are used separately, this signal being absent, each station transfers it’s work piece without waiting .

• The act of checking if the next station is ready, before passing on a work piece is called handshaking, and is used commonly in fully automated processes.

Infra-Red Transmitter & Receiver

Tran

smit

ter

on le

ft s

ide

Rec

eive

r on

rig

ht s

ide


The MPS – Distribution Station



Function :• Always the first station in a MPS chain.• Distribute work pieces from the magazine,

one at a time to the next MPS station.• Ensuring that next station is ready to receive

work piece before transferring the next work piece.

Focuses On :• Rotary actuators.• Vacuum generators & venturi principle.• Vacuum sensor.• Suction cups.• Compact performance valve terminals.

An Overview



Distribution Magazine :• Work piece stack holds up to 8 work

pieces.• Ejection cylinder is normally in

extended position. The work piece is ejected when the ejection cylinder retracts.

• When ejection cylinder retracts, ejector arm clamps the work piece and holds it in place, till it is picked up by the pick-up arm.

Major Components

Ejection cylinder extended

Ejection cylinder retracted



Pick-up Arm :• Uses a suction cup gripper to pick up the work piece

and transfer it to the next station.• Pick-up arm is driven by swivel cylinder, with end

position sensing micro switches.

Major Components



Valve Terminal, Vacuum Generator, Vacuum Sensor :

• Valve terminal includes several components.

3/2 single solenoid valves. Vacuum generator.

• Vacuum sensor is used to check whether work piece has been picked up.

Major Components

Vacuum Sensor

Valve Terminal with Vacuum Generator


The MPS – Testing Station



Function :• Tests each work piece for proper height

and rejects those which are more or less than the acceptable limits.

• Checks and rejects black work pieces.Focuses On :

• Sensors. Optical diffuse sensor. Polarized retro reflective sensor to

avoid false signals from metallic surfaces.

Capacitive sensor. Magnetic sensor. Analog height sensor.

An Overview



Valve Terminal & Work Piece Slides :• Upper slide is for accepted work

pieces. This slide is an air slide with perforations to facilitate smooth transfer of work pieces to the next station.

• The air supply to the upper slide is turned on as soon as a work piece is pushed out from the input receptacle.

• The lower slide is for rejected work pieces.

Major Components



Testing Module :• Capacitive sensor checks presence of work piece.• Optical diffuse sensor looks for non-black work pieces.• Retro reflective sensor checks for any obstruction to

movement of receptacle.• Analog sensor senses the height of the work piece.

Major Components

Receptacle top view Height sensorRetro reflective sensor



Analogue Comparator Module :• Compares the height of the workpiece

against two preset values, representing the lower and the upper limits.

• A good work piece generates a 24V “good” signal, which is sent to the PLC.

• If a “good” signal is not received, the work piece is assumed to be bad.

Major Components


The MPS – Sorting Station



Function :• Sorts the workpieces into three slides,

based on color and material.• Sorting gates are operated by short

stroke cylinders via deflectors.Focuses On :

• Material and color recognition using commonly available sensors.

• Conveyor and diverter methods.• Polarized retro reflective sensor to avoid

false signals from metallic workpieces.

An Overview



Conveyor and sensors :• A fiber optic sensor at the receiving

end is used to check if a part is available. The sensitivity level of this sensor is kept high, so that a black workpiece is also sensed.

• A stopper which is normally extended stops the workpiece just after the part available sensor, so that the material / color of the workpiece can be checked.

• A second fiber optic sensor further down senses if a non black workpiece is present. The sensitivity level of this sensor is deliberately kept low to avoid detecting black workpieces.

• The inductive sensor senses only the metallic workpieces.

Major ComponentsPart available

sensor (fiber optic)

Workpiece not black

sensor (fiber optic)

Stopper

Inductivesensor



Work piece Diverters :• Diverters are used to divert the

workpiece onto one of three slides, based on color and material.

• Two diverters are provided for the first and second slides, while the last slide has a fixed diverter.

Major Components

Diverter 1 Diverter 2



Slide barrier sensor :• Uses a retro-reflective sensor

and reflector with a unique ability to rotate the angle of polarization.

• Reflections from highly reflective workpieces do not cause false signals.

Major Components

Reflector withability to rotatethe angle ofpolarization

Retro- reflectivesensor



Valve Bank :• Three valves are used for the three

cylinders in the sorting station. 3/2 normally open valve for the

stopper. Two 5/2 valves for the diverter

cylinders.

Major Components