book onMechatronic.pdf

8/10/2019 book onMechatronic.pdf

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Rolf Isermann

M e c h a t r o n i c S y s t e m s

u n d a m e n t a l s

W ith 357 Figures

4y Springer


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Contents

List of Symbols xix

1 Integrated Mechanical Electronic Systems

1

1.1 From Mechanical to Mechatronic Systems 1

1.2 Mechanical Systems 6

1.2.1 Mechanical Systems in Mechanical En gin ee ring .. . 8

1.2.2 Mechanical Systems in Precision Mechanic

Devices 9

1.2.3 Micromechanics 9

1.2.4 Mechanical Systems in Apparatus

(Process Engineering) 10

1.2.5 Confinement of Mechatronic Systems 10

1.3 Functions of Mechatronic Systems 11

1.3.1 Design 11

1.3.2 Distribution of Mechanical and Electronic

Functions 12

1.3.3 Operating Properties 13

1.3.4 New Functions 13

1.3.5 Other Developments 14

1.4 Integration Forms of Processes and Electronics 14

1.5 Ways of Information Processing 18

1.5.1 Multi-level Control Systems 18

1.5.2 Special Signal Preprocessing 19

1.5.3 Information Gaining 19


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x Contents

1.5.4 M odel-base d M ethods of Con trol 20

1.5.5 Sup ervision and Fau lt D iagn osis 21

1.5.6 Intelligent System s 22

1.6 De sign Proced ures for M echatron ic Systems 24

1.7 Co ntents of this B oo k 29

2 Fun dam entals of Theor etical M odeling of Techn ical

Processes 33

2.1 Theo retical and Exp erimen tal M ode ling 34

2.2 Classification of Process Elem ents 37

2.2.1 Form s of M atter 37

2.2.2 M ain Flow s and Side Flow s 38

2.2.3 Process Elements with Lum ped Parameters 40

2.2.4 Process Elements with Distributed Parameters . . . . 46

2.3 Fundam ental Equations of Process Elements with Energy

and M atter Flows 46

2.3.1 Balance Equ ations 47

2.3.2 Co nstitutive Eq uations 51

2.3.3 Phenom enological Equations 68

2.4 Energy Balance Equations for Lum ped Parameter

Processes 71

2.4.1 En ergy Balance for M echan ical Systems 71

2.4.2 En ergy Balan ce for The rm al System s (Rigid

Bo dies, Fluids) 77

2.4.3 E nergy Balan ce for Ga ses and Steam 79

2.4.4 Energy Balance for Electrical Systems 83

2.4.5 Co m m on Properties of Balance Equ ations 85

2.5 Co nnection of Process Elem ents 88

2.5.1 No de Equation and M esh Equation 88

2.5.2 Cau sality of Proc ess Elem ents 91

2.6 An alogies between M echanical and Electrical Systems . . . . 94

2.7 Sum m ary 97

2.8 Prob lems 99

3 Fundam ental Equations of the Dyna mics of M echanical

Systems w ith M obile M asses 101

3.1 N ew ton s Law s of Kinetics 102

3.1.1 Translational M otion 102

3.1.2 Ro tational M otion 103

3.2 Principles of M echan ics 106

3.2.1 d A lem ber t s Principle 106

3.2.2 La gra ng e s Eq uations 109


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Contents xi

3.3 Prob lems 114

Mechanical Elements 115

4.1 Ba rs 116

4.2 Spring s 118

4.3 D am pers 121

4.3.1 D am pers with Dry and V iscous Friction 121

4.3.2 Spring-d amp er System s 122

4.4 Be aring s 124

4.4.1 Sliding Bearing s 124

4.4.2 Roller Bearing s 125

4.5 One-m ass Oscil lator (Spring-mass-damp er Systems) . . . . 128

4.5.1 Lon gitudinal Oscillators 128

4.5.2 To rsiona l O scillators 133

4.6 M ulti-mass Oscillators 134

4.6.1 Tw o-m ass Torsional Oscillator with On e Spring . 134

4.6.2 Tw o-m ass Torsional Oscillator w ith Tw o Springs

140

4.6.3 Tw o-m ass Torsional Oscillator with Gear and

One Spring 142

4.6.4 Pow er Trans mission s 146

4.6.5 Belt D rives 151

4.6.6 Ab sorbers and Dam pers 158

4.7 M echan ical Systems with Friction 159

4.8 M echan ical Systems with Back lash 162

4.9 Prob lems 164

Electrical Drives

167

5.1 Ty pes of Electrical Dr ives 167

5.2 Electrom agne ts 170

, 5.2.1 Ty pes of Electrom agnets 170

, 5.2.2 Th e M agn etic Field 171

5.2.3 Static Be hav ior of Sim ple M agn etic Circuits . 173

5.2.4 Dy nam ic Behavior of Simple M agnetic

Circuits 175

5.2.5 Static Beh avior of Electrom agnets 177

5.2.6 D ynam ic Beh avior of Electrom agnets and

Position Con trol 181

5.3 Direct Cu rrent M otors 184

5.3.1 Induced Vo ltage 186

5.3.2 To rque G eneration 187

5.3.3 D ynam ic Beh avior 188


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Contents xiii

6.9.2 Higher Level Feedback Control 289

6.9.3 Adaptive Control 290

6.9.4 Fuzzy Control 290

6.10 Problems 291

Identification of Dynamic Systems

293

7.1 Identification Methods 293

7.1.1 General Procedure 293

7.1.2 Classification of Identification Methods 294

7.1.3 Identification Methods 295

7.1.4 Test Signals 298

7.1.5 Closed-loop Identification 299

7.1.6 Type of Application 299

7.2 Parameter Estimation for Discrete Time Signals 299

7.2.1 Method of Least Squares (LS) 300

7.2.2 Recursive Method of Least Squares (RLS) . . . 303

7.2.3 Modifications of

the

Least Squares Method . . 303

7.3 Parameter Estimation for Continuous Time Signals . . 303

7.3.1 Method of Least Squares 304

7.4 Time-varying Systems 306

7.5 Non-linear Processes 308

7.5.1 Parameter Estimation with Classical

Non-linear Models 308

7.5.2 Artificial Neural Networks 309

7.5.3 Fuzzy-logic Models 323

7.5.4 Grid-based Look-up Tables for Static

Systems 325

7.5.5 Parameter Estimation for Non-continuously

Differentiable Non-linear Processes

(Friction and Backlash) 327

7.6 Problems 331

Models of Oscillations and their Identification

333

8.1 Harmonic Oscillations 333

8.1.1 Single Oscillations 334

8.1.2 Superposition 334

8.1.3 Am plitude Modulation 334

8.1.4 Frequency and Phase Modulation 335

8.1.5 Beating (Libration) 337

8.1.6 Superposition and Non-linear Characteristics . 338

8.2 Identification of Harmonic Oscillations 339

8.2.1 Bandpass Filtering 339


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xiv Contents

8.2.2 Fourier An alysis 340

8.2.3 Co rrelation Fun ctions 340

8.2.4 Fou rier Transform ation 341

8.2.5 Fast Fou rier Transform ation (FFT ) 343

8.2.6 M axim um -entrop y Spectral Estimation 347

8.2.7 Speed Signal An alysis of Co m bustion

Engines 353

8.3 Prob lems 357

9 Sensors 359

9.1 M easuring System 360

9.2 Classification of Senso rs 360

9.3 Sensor Properties 362

9.4 Signal Ty pes, Tran sduc ers, M easuring Am plifiers . . . 363

9.5 Displacement M easurement 364

9.6 Velocity M easurem ent -368

9.7 Acceleration M easurement 370

9.8 Vib ration and Oscillation M easurem ent 372

9.9 Force and Pressure M easurem ent 372

9.10 Torque M easurement 373

9.11 Tem perature M easurement 373

9.12 An alog-to-D igital Con version 376

9.13 Electromagnetic Com patibil ity (EM C) 377

9.14 Integrated and Intelligent Sensors 378

9.15 Prob lems 381

10 Actuators 383

10.1 Basic Structures of A ctuators 384

10.2 Gen eral Survey of Ac tuators 387

10.2.1 Typ es of A uxiliary En ergy 387

10.2.2 Actua tor Beh avior and Con trol 389

10.2.3 Req uirem ents for Ac tuators and Servo-drives . 392

10.3 Electrom echanical Ac tuator Drive s 392

10.3.1 Electrical M otors 393

10.3.2 Electrom agnets 404

10.4 H ydrau lic Ac tuators 406

10.4.1 H ydraulic Actu ation System s 407

10.4.2 Hyd raulic Com ponents and their M odels . . . . 408

10.4.3 M odels of an Hy draulic Servo-axis: An

Example 429

10.5 Pneu m atic A ctuators 439

10.5.1 Pneu m atic Ac tuating Systems 439


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Contents xv

10.5.2 Pneumatic Components and their Models . . . . 442

10.5.3 Model-based Control of

Pneumatic Servo-

axis 452

10.5.4 Models of

Pneumatic Valve 456

10.6 Unconventional Actuators 457

10.6.1 Thermo-bimetals 458

10.6.2 Shaped Memory Alloys 459

10.6.3 Thermal Expansion Elements 462

10.6.4 Electrochemical Actuators 463

10.6.5 Electro-rheological and Magneto-rheological

Fluids 463

10.6.6 Piezoelectric Actuators 465

10.6.7 Electrostrictive and Magnetostrictive

Actuators 469

10.6.8 Micro-actuators 470

10.7 Comparison of Application Areas 471

10.8 Actuators as System Components 474

10.8.1 Ports 475

10.8.2 Integration of Actuator and Process 475

10.8.3 Implemented Functionality 475

10.9 Fault-tolerant Com ponents 476

10.9.1 Fault-tolerance for Com ponents 476

10.9.2 Fault-tolerance for Control Systems 480

10.9.3 Fault Detection for Sensors, Actuators

and Mechatronic Servo-systems 480

10.9.4 Fault-tolerant Com ponents for Mechatronic

Systems 481

10.9.5 Fault-tolerant Sensors 481

10.9.6 Fault-tolerant Actuators 484

10.10 Problems 485

11 Microcomputers

487

11.1 Microcomputer Structure 489

11.2 Standard Processors 490

11.2.1 Standard Processor Architecture 492

11.2.2 Software for Standard Processors 495

11.3 Memory 497

11.4 Interfaces to the Process (Peripherals) 501

11.4.1 Analog Inputs 502

11.4.2 Digital and Binary Inputs 504

11.4.3 Analog Outputs 504

11.4.4 Digital and Binary Outputs 505

11.5 Microcontrollers 506


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xvi Contents

11.5.1 Architecture of Microcontrollers 507

11.5.2 Software for Microcontrollers 510

11.6 Signal Processors 510

11.7 Application-specific Processors (ASICS) 512

11.8 Field Bus Systems 514

11.8.1 Net Topologies 515

11.8.2 Basic Bus Functions 517

11.8.3 OSI (Open System Interconnection)

Reference Model 517

11.8.4 Profibus 519

11.8.5 CAN Bus 523

12 Examples for the Design of Mechatronic Systems:

Modeling Control and Diagnosis

527

12.1 Electromagnetic Actuator: Non-linear Control and

Fault Detection 527

12.1.1 Model-based Compensation of Non-linearities . 527

12.1.2 Electromagnetic Actuator 529

12.2 Electrical Throttle Valve for SI Engines: Modeling

and Fault Diagnosis 535

12.3 Semi-active Vehicle Suspensions 538

12.3.1 Passive Vehicle Suspensions 538

12.3.2 Semi-active Suspensions 543

12.3.3 Dynamic Models of

Quarter-car 549

12.3.4 Identification of a Quarter-car Model 551

12.3.5 Suspension Control 554

12.3.6 Simulations of

Semi-active Two-chamber

Air Spring 559

12.4 Electromechanical Disc Brake (EMB) 560

12.4.1 Introduction 560

12.4.2 Wheel Module 562

12.4.3 Brake Model 564

12.4.4 Simplified Brake Model 567

12.4.5 Simulation and Measurement 568

12.5 Control Prototyping and Hardware-in-the-loop

Simulation 569

12.5.1 Simulation Methods 569

12.5.2 Rapid Control Prototyping for Engine Control

571

12.5.3 Hardware-in-the-loop Simulation for Diesel

Engines 572

12.6 Industrial Robot 577

12.6.1 Modeling 578


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Contents xvii

12.6.2 Control 583

12.6.3 System Structure 585

Outlook 587

References 589

Index 617

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