Introduction to Mechatronics

COMPUTING

Prof.Dr.. Fatih M. Botsalı

Prof.Dr
MECHATRONIC SYSTEM
COMPUTING ELEMENT

Control
Software

COMPUTER

SENSOR ACTUATOR

PHYSICAL SYSTEM
SAMPLE MECHATRONIC
SYSTEM
 COMPUTING
ARCHITECTURES

Microprocessors-Microcontrollers
Microprocessors-

Digital Signal Processor-
Processor-DSP

Programmable Interface Controller (PIC)

Programmable Logic Controller
Controller--PLC

Digital Circuits(Program
Circuits(Program Array Logic Controller –PAL,
Program Logic Array-
Array-PLA)

PC-
PC-IPC

Single Board Computer

Analog circuits (OPAMP’s and transistors)
transistors)
 MICROPROCESSOR’S
• A computer processor on a microchip. It's sometimes
called a logic chip. It is the "engine" that goes into
motion when you turn your computer on. A
microprocessor is designed to perform arithmetic and
logic operations that make use of small number-holding
areas called registers.
• Typical microprocessor operations include adding,
subtracting, comparing two numbers, and fetching
numbers from one area to another. These operations
are the result of a set of instructions that are part of
the microprocessor design.
 MICROPROCESSOR’S
Examples
•Intel 80486, Pentium etc.
•Motorola 68030, Power PC
•Risc based
MICROPROCESSOR’S
CPU
Registers RAM | ROM

program data

storage storage

Control, data, address bus

ALU

Control
unit
output input
unit unit
 DIGITAL SIGNAL
PROCESSORS (DSP)
(DSP)

A digital signal processor (DSP) is a type of
coprocessor that is incredibly fast and
powerful..
powerful

Used in sound
sound,, speech
speech,, music
music,, video, image
processing applications.
applications.

A DSP is unique because it processes data in
real time. This real-
real-time capability makes a
DSP perfect for applications where there is
no tolerance for delays.
delays.
 DIGITAL SIGNAL
PROCESSORS (DSP)

In the old generation cell phones two people couldn't talk at
once.. One had to wait until the other person was through
once
talking.. If they both spoke simultaneously,
talking simultaneously, the signal was cut
out.. With today's digital cell phones
out phones,, which use DSP, speakers
can talk simıltaneously.
simıltaneously. The DSP chips inside cell phones can
process sounds so rapidly that one can hear something as
quickly as he can say it - in real time.

In digital cell phones,
phones, there is no echo,
echo, and no static.
static. The DSP
takes a real-
real-world signal
signal,, like sound,
sound, and mathematically alters
it to improve the sound.
sound. The DSP compresses the data and
removes the background noise so voice travels at a higher
rate.
 COPROCESSOR

A special
special--purpose microprocessor that assists the CPU
in performing certain types of operations.
operations. For example
example,,
a math coprocessor performs mathematical
computations,, particularly floating
computations floating--point operations
operations..
Math coprocessors are also called numeric and floating-
floating-
point coprocessors.
coprocessors. The running software must be
written to take advantage of the coprocessor.
coprocessor.

In addition to math coprocessors,
coprocessors, there are also
graphics coprocessors for manipulating graphic images.
images.
These are often called accelerator boards.
boards.
 DIGITAL SIGNAL
PROCESSORS (DSP)

The result is crystal clear sound
sound,, with no annoying echoes.
echoes.

A DSP takes a digital signal and processes it to improve the
signal.. The improvement may be clearer sound
signal sound,, sharper
images,, or faster data. And that ability to improve signals is
images
making new breakthroughs such as Internet music and
broadband to the home possible.
possible.

A DSP on the other hand is a microprocessor
microprocessor.. A DSP would
need a suitable circuit built around it to work.
DSP APPLICATIONS
PROGRAMMABLE INTERFACE
CONTROLLER--PIC
CONTROLLER

The PIC was developed as a peripheral
controller..
controller

PIC (Peripheral Interface Controller) is the IC
which was developed to control peripheral
devices, alleviating the load from the main CPU.

Compared to a human being, the brain is the
main CPU and the PIC is equivalent to the
autonomic nervous system.
PROGRAMMABLE INTERFACE
CONTROLLER--PIC
CONTROLLER

The PIC is convenient for making
calculations. The memory, the
input/output ports and so on are
incorporated into the IC.

The efficiency and the functions
are limited, but the PIC can do the
job of many IC's with software.
so, the circuit can be compact.
PROGRAMMABLE INTERFACE
CONTROLLER--PIC
CONTROLLER

The PIC, like the CPU, has
calculation functions and
memory, and is controlled
by the software.

However, the throughput
and the memory capacity
are low.
PROGRAMMABLE INTERFACE
CONTROLLER--PIC
CONTROLLER

Depending on the kind of PIC, the maximum
clock operating frequency is about 20 MHz and
the memory capacity (to write the program) is
about 1K to 4K words. The clock frequency
determines the speed at which a program is read
and an instruction is executed.
 WHAT IS A PLC?

A programmable logic controller (PLC) or
programmable controller is a digital
computer used for automation of
electromechanical processes.
processes.

The PLC was invented in response to the
needs of the American automotive
manufacturing industry.
industry. Programmable
controllers were initially adopted by the
automotive industry where software
revision replaced the re-
re-wiring of hard-
hard-wired
control panels when production models
changed..
changed
 WHAT IS A PLC?
A PLC is an example of a real time system since output
results must be produced in response to input
conditions within a bounded time, otherwise
unintended operation will result.
 WHAT IS A PLC?

The functionality of the PLC has evolved over the
years to include sequential relay control, motion
control, process control, distributed control systems
and networking. The data handling, storage,
processing power and communication capabilities of
some modern PLCs are approximately equivalent to
desktop computers.

The main difference from other computers is that
PLCs are armored for severe conditions (such as dust,
moisture, heat, cold) and have the facility for
extensive input/output (I/O) arrangements. These
connect the PLC to sensors and actuators.
 WHAT IS A PLC?

PLCs read limit switches, analog process variables (such as
temperature and pressure), and the positions of complex
positioning systems. Some use machine vision. On the
actuator side, PLCs operate electric motors, pneumatic or
hydraulic cylinders, magnetic relays, solenoids, or analog
outputs.

The input/output arrangements may be built into a simple
PLC, or the PLC may have external I/O modules attached to a
computer network that plugs into the PLC.

PLCs have built in communications ports usually 9-
9-Pin RS232,
and optionally for RS485 and Ethernet. Modbus,
Modbus, BACnet or
DF1 is usually included as one of the communications
protocols.
 PLC
Uses relay logic
Inputs and outputs are actual relays
Simulate thousands of relays,
May contain counters and timers
 HISTORY

First applications 1960’S

After 1970’s by using microprocessors more advanced
PLC’s are introduced

After 19080’s more compact and user friendly
(programmable by software)
 PLC
• Before the PLC, control, sequencing, and safety
interlock logic for manufacturing automobiles was
accomplished using hundreds or thousands of
relays, cam timers, and drum sequencers and
dedicated closed-loop controllers.
• The process for updating such facilities for the yearly
model change-over was very time consuming and
expensive, as electricians needed to individually
rewire each and every relay.
 PLC
• PLCs are well-adapted to a range of automation
tasks. These are typically industrial processes in
manufacturing where the cost of developing and
maintaining the automation system is high relative
to the total cost of the automation, and where
changes to the system would be expected during its
operational life.
• Unlike general-purpose computers, the PLC is
designed for multiple inputs and output
arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to
vibration and impact.
 PLC PROGRAMMING
Early PLCs were designed to replace relay logic
systems. These PLCs were programmed in "ladder
logic", which strongly resembles a schematic diagram
of relay logic. This program notation was chosen to
reduce training demands for the existing technicians.

Modern PLCs can be programmed in a variety of ways,

from ladder logic to more traditional programming
languages such as BASIC and C. Another method is
State Logic, a very high-level programming language
designed to program PLCs based on state transition
diagrams.
 PLC PROGRAMMING
• Under the IEC 61131-3 standard, PLCs can be
programmed using standards-based programming
languages. A graphical programming notation called
Sequential Function Charts is available on certain
programmable controllers. Initially most PLC's utilized
Ladder Logic Diagram Programming, a model which
emulated electromechanical control panel devices (such
as the contact and coils of relays) which PLC's replaced.
This model remains common today.
• Most modern PLCs can communicate over a network to
some other system, such as a computer running a SCADA
(Supervisory Control And Data Acquisition) system or
web browser.
PLC
 PARTS OF A PLC
• Inputs: limit switches;
pushbuttons; sensors; other
on/off devices; analog
• Outputs: motor; valve; relay;
other actuators; PID
• CPU–executes logic &
sequencing functions; similar
to microprocessor of PC’s
• Memory–stores program(s);
stores data/status; stores
executive program
 PARTS OF A PLC
• Power supply–115 VAC; can
regulate much higher voltage &
power
• Programming device
(programmer): teach pendant;
PC-type units
PARTS OF A PLC
 OPERATION OF A PLC

Read inputs

Execute control programs

Revise outputs
 OPERATION OF A PLC

Dependent on number & complexity of control

functions: memory used; number & type of I/O

Can vary from 1 msec to 100msec

If too slow, system may malfunction
 RESPONSE TIME

Total response time is one of the significant

criteria in choosing control devices
RELAYS
PLC INSTEAD OF RELAYS
Switch

Coil

Ladder diyagramı:
SAMPLE LADDER DIAGRAM
 PLC PROGRAMMING
PLC programs are typically written in a special
application on a personal computer, then downloaded
by a direct-connection cable or over a network to the
PLC. The program is stored in the PLC either in battery-
backed-up RAM or some other non-volatile flash
memory. Often, a single PLC can be programmed to
replace thousands of relays.
PLC CONTROL FUNCTIONS
• Sequencing
• Timing
• Counting
• Arithmetic
• Data manipulation
• Communication
 PLC ADVANTAGES
• PLC programming easier than wiring relay control
panel
• PLC can be reprogrammed; conventional components
must be rewired or scrapped
• PLC takes less floor space than relay panels
• PLC maintenance easier; reliability greater
• PLC can be more easily connected to plant computer
system
• Lower overall cost
REGISTERS
 PLC VS PIC

A PLC is an industrial grade computer. A PLC is
supplied with power (usually 80-
80-240VAC) and it will
accept inputs, and it has outputs, relays
relays. There are
of course other options.

Some PLCs provide 24Vdc out for sensors, most
have some form of comunication protocol. Some
even offer onboard ethernet.
ethernet.

PLCs are usually very robust by design. The inputs
and outputs are often protected and the unit is not
very susceptible to electrical noise or interference.
 PLC VS PIC

PLCs come in a variety of sizes and features and
range greatly in price. A simple PLC might cost $100
and a large unit might cost over $5000. PLCs do a
variety of jobs.

A PIC on the other hand is a microcontroller. A PIC
would need a suitable circuit built around it to work
like a PLC.

You can't connect most sensors directly to a PIC.
 PLC VS PIC

You must design the electronics and there is a cost
involved in designing the electronics around the PIC.
You have to write your code and debug it. With a
PLC you simply buy it and program it.

PLC’s are usually used for one time projects. PICs
are used when the project is large and there will be
a cost savings or when you want sell the electronics.
 Programmable Array
Logic (PAL) Controller

Bir lojik entegre devre topluluğudur.
 Generic Array Logic

Generic Array Logic - (GAL) Yeni bir PAL türüdür.
EEPROM depolama hücreleri tabanlıdır. GAL’ler
silinebilir yeniden programlanabilir. Bir PAL serisinin
yerine kullanılabilir.
 PROGRAMMABLE ARRAY
LOGIC (PAL) CONTROLLER

Programmable Array Logic (PAL) is used
to describe a family of programmable
logic device semiconductors used to
implement logic functions in digital
circuits introduced by Monolithic
Memories,, Inc
Memories Inc.. (MMI) in March 1978.

PAL devices consisted of a small PROM
(programmable read- read-only memory)
memory) core
and additional output logic used to
implement particular desired logic
functions with few components.
components.
 PROGRAMMABLE ARRAY
LOGIC (PAL) CONTROLLER

Using specialized machines,
machines, PAL devices were "field
field--
programmable".
programmable ". Each PAL device was "one
one--time
programmable"" (OTP), meaning that it could not be
programmable
updated and reused after its initial programming
programming.. (MMI
also offered a similar family called HAL, or "hard array
logic",
logic", which were like PAL devices except that they
were mask
mask--programmed at the factory.)
factory.)
 PROGRAMMABLE ARRAY
LOGIC (PAL) CONTROLLER

PALs were programmed electrically using binary
patterns (as JEDEC ASCII/hexadecimal
ASCII/hexadecimal files)
files) and a
special electronic programming system available from
either the manufacturer or a third
third--party
party,, such as
DATA/IO.
 GENERIC ARRAY LOGIC

The Generic Array Logic (also known as GAL) device was
an innovation of the PAL and was invented by Lattice
Semiconductor..
Semiconductor

The GAL based on EEPROM storage cells was an
improvement on the PAL because one device was able
to take the place of many PAL devices or could even
have functionality not covered by the original range.
range.

Its primary benefit,
benefit, however,
however, was that it was eraseable
and re-
re-programmable making prototyping and design
changes easier for engineers
engineers..
 PC’S AND IPC’S

Preferred in one time projects. (R&D)

Preferred in very complex mechatronic systems.
systems.

Use of Plug
Plug--In Data Acquisition cards
 PC’S

A personal computer (PC) is any general-
general-purpose
computer whose size, capabilities,
capabilities, and original sales
price make it useful for individuals,
individuals, and which is
intended to be operated directly by an end user user,, with no
intervening computer operator.
operator. This is in contrast to the
batch processing or time-
time-sharing models which allowed
large expensive mainframe systems to be used by many
people,, usually at the same time, or large data
people
processing systems which required a full full--time staff to
operate efficiently.
efficiently.
 PC’S

Software applications for PC’s include word processing
processing,,
spreadsheets,, databases,
spreadsheets databases, Web browsers and e-mail
clients,, games,
clients games, and special-
special-purpose software.

Modern personal computers often have high-
high-speed or
dial--up connections to the Internet.
dial

Personal computers can be connected to a local area
network (LAN) either by a cable or wirelessly.
wirelessly.

While early PC owners usually had to write their own
programs to do anything useful with the machines,
machines,
today's users have access to a wide range of commercial
and non-
non-commercial software which is provided in ready-
ready-
to
to--run form.
 IPC’S

Industrial PC's (IPC's)
IPC's) are Personal Computers designed to
be used in an rugged industrial environment. The difference
between them and ordinary desktop PC's are as under:
1. Generally housed in a rugged rack mounting enclosure having high
resistance to vibration, temperature, dust and noise.
2. Heavy duty cooling fans with dust filters
3. High fault tolerant and rugged circuitry. In some cases, redundant
power supply will also be used.
4. The CPU and its associated chip sets are not part of the motherboard.
A separate CPU Card (daughter board) has to be plugged in the mother
board.
5. Motherboard has a large number of ISA and PCI Slots for plugging in
add on cards for industrial applications data acquisition, data logging
cards, etc.
 IPC

Industrial 19'' Rackmount PC 2U 4xPCI Slots, Intel P4 2.8GHz

Processor, 256Mb DDR RAM, LAN, 40Gb HDD, CD-ROM, FDD,
300W ATX PSU $ 783
SINGLE BOARD COMPUTERS
• Single-board computers (SBCs) are complete
computers built on a single circuit board.
• The design is centered on a single or dual
microprocessor with RAM, IO and all other features
needed to be a functional computer on the one board.
• The first true single-board computer called the "dyna-
micro" was based on the Intel C8080A, and also used
Intel's first EPROM, the C1702A.
SINGLE BOARD COMPUTERS
• With the development of PCs there was a sharp shift
away from SBC’s .
• The recent availability of advanced chip sets providing
most of the I/O features as embedded components
allows motherboard manufacturers to offer
motherboards with I/O traditionally provided by
daughterboards. Most PC motherboards now offer on-
board support for disk drives including IDE and SATA with
RAID, graphics, Ethernet, and traditional I/O such as serial
and parallel ports, USB, and keyboard/mouse support.
SINGLE BOARD COMPUTERS
• Plug-in cards are now more commonly high performance
graphics cards (really graphic co-processors), high end
RAID controllers, and specialized I/O cards such as data
acquisition and DSP (Digital Signal Processor) boards.
SINGLE BOARD COMPUTERS
SINGLE BOARD COMPUTERS
SINGLE BOARD COMPUTERS

Advantages
Normal bilgisayarda çalışan
yazılım çalışabilir
Ucuzdur
Küçük hacimlidir
OPAMP’S
 OPAMP’S
• An operational amplifier, (OPAMP) is a DC-coupled
high-gain electronic voltage amplifier with differential
inputs and, usually, a single output.
 OPAMP’S
• Typically the output of the op-amp is controlled either
by negative feedback, which largely determines the
magnitude of its output voltage gain, or by positive
feedback, which facilitates regenerative gain and
oscillation. High input impedance at the input terminals
(ideally infinite) and low output impedance (ideally
zero) are important typical characteristics.
• OPAMP’S are among the most widely used electronic
devices today, being used in a vast array of consumer,
industrial, and scientific devices.
 OPAMP’S
• Many standard IC op-amps cost only a few cents in
moderate production volume; however some
integrated or hybrid operational amplifiers with special
performance specifications may cost over $100 US in
small quantities.
• OPAMP’S can perform addition/substraction,
differentiation, multiplication/division, negation
operations.
 OPAMP’S
Integration
 OPAMP’S
Addition
 OPAMP’S
Differentiation
 OPAMP’S
Difference
 OPAMP’S
Instrumentation amplifier. Combines very high input
impedance, high common-mode rejection, low DC offset,
and other properties used in making very accurate, low-
noise measurements