4.Sensors Mecatrónica

8/9/2019 4.Sensors Mecatrónica

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1540 Introduction To Mechatronics: Slide 1Stefan B. Williams

Introduction to Mechatronics

Mech-1540

Sensors 1


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Schedule of Events

Q 2 of Assign 2MID SEMESTER BREAK

Spare19/614

Due 13/6Major Assignment12/613

Case Study : Unmanned Air/Land/Sea Vehicles5/612

Case Study : Formula SAE29/511

Active Sensor Systems (Graham Brooker)22/510

Due 16/5Assignment 2 - Control and Modelling15/59

Q 4 of Assign 2System Modelling and Control8/58

Q 3 of Assign 2Computer – Software and Design Tools1/57

6

5

4

3

2

1

Week

17/4

10/4

3/4

27/3

20/3

13/3

Date

Computer – Hardware

Assignment 1 – Design Exercise

Sensors

Actuators

Design Process

Introduction

Content

Q 1 of Assign 2

Due 11/4

Q 3 of Assign 1

Q 2 of Assign 1

Q 1 of Assign. 1

Assignment Notes


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Industrial Sensors

• Proximity

– Mechanical

– Optical

– Inductive/Capacitive

• Position/Velocity – Potentiometer

– LVDT

– Encoders

– Tachogenerator • Force/Pressure

• Vibration/acceleration


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Definitions

• Accuracy: The agreement between the actual value and

the measured value

• Resolution: The change in measured variable to which

the sensor will respond• Repeatability: Variation of sensor measurements when

the same quantity is measured several times

• Range: Upper and lower limits of the variable that can be

measured• Sensitivity and Linearity


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Proximity Sensors

• Widely used in general industrial automation

– Conveyor lines (counting,jam detection, etc)

– Machine tools (safety interlock, sequencing)

• Usually digital (on/off) sensors detecting thepresence or absence of an object

• Consist of:

– Sensor head: optical, inductive, capacitive

– Detector circuit

– Amplifier

– Output circuit: TTL, solid state relay


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Mechanical Proximity Switches

• Essentially amechanical switch

• On/off operation only• Two general modes

– Normally Open (NO)

– Normally Closed (NC)

• Come in a wide variety

of mechanical forms

• For a wide range of uses

Actuator

Common

Normally

Closed

Normally

Open


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Example Mechanical Proximity

Switches


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When to Use Mechanical

Proximity Switches

• Where physical contact is possible

• Where definitive position is required• In operation-critical or safety-critical

situations

• Where environment conditions preclude the

use of optical or inductive sensors


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Applications and Use of

Mechanical Proximity Switches

• Easy to integrate into machinery of all types

• Requires contact (thus wear)

• Range of voltages: DC 0-1000V, AC, etc.• Very robust (explosion proof if required)

• Usually used as:

– Limit switch

– Presence/absence indicator

– Door closed/open


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Places You Find Mechanical

Proximity Switches !


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Optical Proximity Sensors

• Consist of a light source (LED) and light detector(phototransistor)

• Modulation of signal to minimize ambient lightingconditions

• Various models: 12-30V DC, 24-240V AC, power

• Output: TTL 5V, Solid-state relay, etc.

Demodulator

Amplifier

Modulator Power

Output

Mixer Signal

Power Supply

Load


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Operational Modes

• Through Beam:

– Long range (20m)

– Alignment is critical !

• Retro-reflective – Range 1-3m

– Popular and cheap

• Diffuse-reflective – Range 12-300mm – Cheap and easy to use


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Example Optical Proximity I

Optical Fibre

Delivery System


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Example Optical Proximity II

Slot Beam

Systems


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Other Optical Devices

Light

Curtain

Collision Detection


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Ultrasonic Proximity Sensors

• Use sound pulses• Measures amplitude and time

of flight

• Range provides more than

on/off information• Frequencies 40KHz-2MHz

Pulse

Echo

Vibrating Membrane

(metal or ceramic)

Sensor Object


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When to use Ultrasonic Sensors

• Provide range data directly:

• Level monitoring of solid and liquids

• Approach warning (collisions)

• Can (usually) work in heavy dust and water

• Ambient noise is potentially an issue

http://www.automationsensors.com/


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Example Applications

Car Wash

Application

Paper roll

Thickness Monitor

Waste water

flow volume


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Inductive and Capacitive

Proximity Sensors

• Inductive sensors use change in local

magnetic field to detect presence of metal

target

• Capacitive Sensors use change in local

capacitance caused by non-metallic objects

• Generally short ranges only

• Regarded as very robust and reliable


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Example Inductive Sensors I

Detection of

open/close functions

Detection of

rotation


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Example Inductive Sensors II

Bulk mounted inductive

sensors. Detect presence of

object without contact.

Range 3mm +/- 10%


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Example Capacitive Sensors

Panel Mounted Capacitive

Sensor. Can detect wood,

plastic and metal.Range 3mm-25mm

Flat mounted Capacitive

Sensor. Used for detecting

panels of glass.

Range=10mm +/- 10%


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Position and Velocity

Measurement

• Position and velocity measurementis often required in feedback loops

• For positioning, and velocity control

• Position measurement: – Potentiometers

– LVDT

– Encoders

• Velocity Measurement:

• Tachometer


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Potentiometers

R Vin

Vout

An analog sensor

Works as a voltage divider


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Types of Potentiometer

• Wirewound

– Wiper slides along coil of Ni-chrome wire

– Wire tends to fail, temperature variations

• Cermet – Wiper slides on conductive ceramic track

– Better than wire inmost respects

• Plastic film

– High resolution

– Long life and good temperature stability


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When to use a Potentiometer

• Require analog signal for control

• Require absolute positional information

• Low cost

• Temperature and wear variations

• Not in dusty or wet environments


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LVDT Signal Conditioning

• Uses AC modulation,

demodulation and

phase comparison

• Available in a singlemonolithic package

Power Supply

Carrier Oscillator

AmplitudeControl

LVDT

CurrentAmplifier

Demodulator

Phase

Shifter

Zero

Set

AC Power


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Example LVDTs

Spring-loaded

Standard for use

In hydraulic cylinders

Free core LVDTs for

use in hostile environments

And total emersion


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When to use an LVDT

• High accuracy

• Linear operation (synchro resolver is

equivalent rotary LVDT)

• Harsh environment

• Analog position control

• Embedding (in cylinder for example)


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Optical Encoders

• Encoders are digital Sensors commonly used toprovide position feedback for actuators

• Consist of a glass or plastic disc that rotates

between a light source (LED) and a pair of photo-

detectors• Disk is encoded with alternate light and dark sectors

so pulses are produced as disk rotates


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Encoder Internal Structure


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Incremental Encoders

• Pulses from leds are

counted to provide

rotary position

• Two detectors are usedto determine direction

(quadrature)

• Index pulse used to

denote start point• Otherwise pulses are

not unique


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Absolute Encoders

• Absolute encoders havea unique code that can

be detected for every

angular position

• Often in the form of a“grey code”; a binary

code of minimal change

• Absolute encoders are

much more complexand expensive than

incremental encoders


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Encoder processing

• Need a squaring circuit

to digitise signal

• A counter and index

monitor • Generally available in

monolithic form

• Often with algorithms

for control externallyprogrammable


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When to Use an Encoder

• Require accurateposition information:

– 10,000 line incremental

– 360 line absolute

• Digital feed-back loop

• Compact and

reasonably rugged (not

as good as inductive)

• Linear encoders also

available


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Tachometers

• Measurement of rotaryspeed using a DCgenerator

• Essentially a motorrunning in reverse

• Used to be common tohave these attached tomotors to enable directanalog feedback

• Much less common nowwith digital control (useincremental encoders)

Tacho generator for large

industrial plant (GE)


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Force and Pressure

• Force and Pressure generally measuredindirectly through deflection of an alternate

surface

• Mechanism include: – Physical motion and measurement using (eg) an

LVDT

– Strain gauges (metal that changes resistance when

stressed) – Piezo electric materials that generate a current

when deformed


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LVDT Load Cell

Table ForceSpring or Piston

LVDT

Outer

Platform


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Strain Gauge Bridge

R R R RGF

L L

R R GF

ε

ε

∆ ∆= =∆

∆ = ⋅ ⋅Tension

Strain Gauges

( )

3 2

3 4 1 2

1 2 4

3

, ,

4

2

meas

exc

G

G

meas

meas exc

V R RV R R R R

assume R R R R

R R RV

thenGF V V

ε

= − + +

= =

= + ∆−=

−


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Example Load Cells

Reaction torque

load cell

Axial load cell

http://www.entran.com/ltoc.htm

Subminature

Load cells


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Sub-miniature Load cells

All signal conditioning

and amplification integrated

with the sensor Load cell bridge structure


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Piezo Load Cells

• Distortion of crystal,

either quartz or BaTiO3

• Used for accuratemeasurement of small

loads

• Come in the form of:

• single axis load washers• or multiple axis load

washers and tables


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Pressure

• Pressure measured by: – Pitot tube and

– Deformation of fixed

membrane

• Deformation measuredusing same methods as

for force:

• Spring (manometer)

• Piezo distortion• Strain gauges

Miniature

Industry IP69

High Temperature


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Acceleration

• Acceleration is alsomeasured via the force

exerted by an

accelerating mass

• Distortion of a piezo• Motion of a cantilever

• Strain on mass

restraints

• Accelerometers mainlyused to measure

vibration

Single Axis,

10,000g

Shielded forSevere

environment

EMI

shielded


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Tri-axial Accelerometers

• Triaxial accelerometers

used in mobile systems

– In high-performance cars

– Inside rotating elementsof turbines

– In aircraft elements

• Provide vibration

information• Provide short-term

position data

Triple axis

Accelerometer

For racing cars


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Silicon Machined

Accelerometers

Cantilever

beams

Used in eg air-bags


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Silicon Gyroscopes

• Structural arrangementof silicon which records

centrifugal acceleration

and thus angular speed

• Use strain-gaugebridges and/or piezo

structure to record

deformations

• Multiple componentelements to calibrate

other accelrations


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Inertial Systems

• Many different types of accelerometer andgyroscope systems

• Mechanical bodies, fibre optic, etc

• Together in an orthogonal arrangement ofaccelerometers and gyroscopes, thesecomprise an inertial measurement unit (IMU)

• An IMU that is used for navigation is called aninertial navigation system (INS)

• These are widely used in aircraft and missilenavigation and guidance


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Aerospace INS

http://www.littongcs.com/products/2guidance/space/overview.html

Aircraft

Ballistic

Missile

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