ME411-Syllabus / Final projects PDF

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Syllabus and final projects of course described in document...

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University of Illinois at Chicago College of Engineering Department of Mechanical and Industrial Engineering ME 411- Mechatronics I (cross listed with IE 411)

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Instructor: Professor Sabri Cetin, Phone: (312) 996-9611, Mobile: 708-903-9784 [email protected], Office: ERF 3037. Office Hours: M 12:00 noon - 4 :00 pm Lecture Room and Times: LCC-C003 , MW 4:00-4:50pm Lab Room and Times: SEL 4239, Sign up one of the lab times available. Teaching Assistants: Assigned at the beginning of each semester: 312-413-7410, Room: SEL 4239 Catalog Description: Physical principles of transduction and sensing, current state of art components in sensors, actuators, electronics, and microprocessor based controls. Analyze, design, build and test computer controlled electro-mechanical systems involving sensors, actuators, embedded control computer hardware and software. Textbook: Mechatronics with Experiments, Cetinkunt, S., John Wiley and Sons, 2015, ISBN: 978-1-118-80246-5. Course Blackboard: www.blackboard.uic.edu. All submissions (homework, lab report, quizes, final project report) will be done electronically thru Blackboard.uic.edu, as PDF file. No paper copies will be accepted. Lab results and final project will be demonstrated to the TAs in the lab. Lectures are based on the textbook. Additional lecture notes will be posted on the blackboard occasionally. Prerequisites: ME 312 or graduate student in good standing. Grading: Labs (50%), Two Exams (30%), Final Project (20%) . The lab projects involve design, build and testing of various computer control circuits and software in increasing complexity as the semester progresses. These lab projects are done by each student individually or in small groups and takes about two to three weeks per lab project.

Week # Topics Covered: Week 1 Lecture 1 Introduction to Mechatronic Systems. Pages 1-16. Lecture 2 Diesel Engine Electronic Control: Pages 16-31. Week 2 Lecture 3

Lecture 4 Week 3 Lecture 5

Lecture 6 Week 4 Lecture 7 Lecture 8

Modeling and Simulation of Dynamic Systems: Differential equations, Numerical solution using Euler and Runga-Kutta methods, linearization, Laplace Transforms, Block Diagram Concept, pp. 105-120 from Controls Book Text Notes. Matlab and Simulink: Pages 805-821 Numerical Methods for Simulating Dynamic Systems and Controls Using Matlab and Simulink: Numerical Integration of Differential Equations, Solutions of Difference Equations, Control Algorithms: analog and digital implementations, System Simulation. pp. pp 822-836 Matlab Simulink: modeling and simulation. Pages 836-856.

Closed loop control concepts: closed loop and open loop embedded control systems PID Control: P,I,D, PD, PI, Lead-lag compensators, pp. 97-111 PID controls, Pages 111-123

Week 5 Lecture 9

2 Practical PID controllers and modifications, effect of Coulomb friction, backlash and deadband in motion control systems, Pages 123-124, Supplemental Tech Notes. Digital implementation of PID controls and analog controls: Pages 125-128. Lecture 10: Exam #1

Week 6 Lecture 11

Lecture 12 Week 7 Lecture 13 Lecture 14 Week 8 Lecture 15 Lecture 16 Week 9 Lecture 17 Lecture 18 Week 10 Lecture 19 Lecture 20 Week 11 Lecture 21 Lecture 22 Week 12 Lecture 23 Lecture 24 Week 13 Lecture 25 Lecture 26

Week 14 Lecture 27 Lecture 28 Week 15 Lecture 29 Lecture 30

Mechanism Design for Automation Systems: gear reducers, motion conversion mechanisms. Pages 133-143 Automotive powertrain: engine and transmission control; Pages 143-147, pp. 16-31 Actuator Sizing; Linear positioning systems, CNC lead screw drive systems, Pages 155-162 Servo positioning control, CNC machine and robotic manipulator applications. Pages 9-12, Supplemental Tech Notes. Exam #2

Kirchoff’s Current and Voltage Law, Basic Passive Circuits: RLC. Pages 245-249, 749-754 Introduction to the Labs. Concept of Impedance: generalization of “resistance” with transfer function. Pages 252-260 Semiconductors, diodes, transistors. Pages 262-282 OP-AMP circuits, analog circuits: Low pass and high pass filter passive and active (Op -amp) filters. Pages 282-283, 290-297, Lab # 1 due OP-AMP circuits continued: Pages 297-305 Analog and Digital Circuit Interfaces: ADC DAC, PWM, DI, DO. Pages 314-324, Lab #2 Sensors and Measurement Systems: operating principles and current state of art, Position Sensors. Pages 329-351 Speed, Acceleration, Temperature, Pressure, Force, Toque sensors Pages 351-381, Lab#5

Sensors: temperature sensors, flow rate sensors. Pages 381-392 Vision Systems, Inertial Measurement Units (IMUs), and GPS. Pages 394-403

Microcontrollers: PIC 18F452 and Arduino, CPU, Memory, Bus. Pages 207-218 Architecture, Basic Computer Model Concept, Microcontroller Pinout, Register Based I/O Pages 218-232, Lab # 3 due Microcontroller: Digital I/O, Analog I/O, Pages 232-235 Microcontroller: Interrupt Vector Table (IVT), and Interrupt Handling, Timers: input capture, output compare match, PWM output, PWM input ; Pages 235-243. Lab#4 Final Project: Hardware in the loop simulation (HIL), real-time PID control implementation and testing, and CAN bus. Review of the course. Pages 1 – 887. Lab#6

3 the Remarks: Study the material before lectures. Work on examples and problems. Come to lecture almost completely understood the material and perhaps some questions you might have and discuss next level of “what if” type advanced topics on the matter. “Does it work ? “ is our ultimate test – not just on paper or simulation, but in actual hardware – does it work ? Does it work well and reliable ? You can work as a team, discuss all class matters with your classmates and share your work and knowledge – sharing and team work are good. But, you should not just copy from someone else. We all know the difference between working together, helping each other and “ copying”.

1. Listen and Discuss – Lectures by the Professor and TA meetings. 2. Read – Textbook, Lecture notes, Other supplemental material 3. Do - Homework, Labs; active learning. All with focus. Ancient Chinese Proverb: “Heard = Forgot, See = Remember, Did= Know”. In this journey, I am your guide.

Homework # HWK 1 HWK 2 HWK 3 HWK 4 HWK 5

Problems 1.1, 1.2, 1.3. 1.4 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8 3.1, 3.2, 3.4, 3.5, 3.6, 3.7, 3.10, 3.11 4.1, 4.2, 4.3, 4.4, 5.1, 5.3, 5.5, 5.10, 6.1, 6.2, 6.3, 6.5, 6.6, 6.7, 6.9, 6.10,

Due Date

4 Labs: Components Needed. Lab descriptions at the Appendix of the textbook. Lab #

LAB 1

LAB 2

LAB 3

LAB 4

LAB 5

LAB 6

Item Resistors Assortment Kit Capacitors Assortment Kit Inductor Breadboard Set of connection wires Resistors Assortment Kit BJT transistor, NPN type Breadboard Set of connection wires Resistors as calculated Capacitors as calculated Breadboard Set of connection wires LM358 Op-Amp IC Resistor 820k Ohms Resistors as calculated Capacitors as calculated Breadboard Set of connection wires LM358 Op-Amp IC Potentiometer (2k Ohms) Resistor 4.7k Ohms Resistor 1k Ohms Battery 9V Breadboard Set of connection wires LM358 Op-Amp IC Resistor 1k Ohms Resistor 4.7k Ohms Resistor 100k Ohms Resistor 470 Ohms Capacitor 0.22 microF Battery 9V Breadboard Set of connection wires

Quantity 1 1 1 1 1 set 1 1 1 1 set 1 1 1 1 set 1 1 1 1 1 1 set 1 1 1 1 2 1 1 set 3 8 4 4 1 2 2 1 1 set

Part No. 81832 130232 386361 20723 19290 81832 38359 20723 19290 81832 130232 20723 19290 23966 691569 81832 130232 20723 19290 23966 41865 691024 690865 198791 20723 19290 23966 690865 691024 691340 690785 25540 198791 20723 19290

Supplier Jameco Electronics (www.jameco.com)

Lab Supplies:

Item Resistors Assortment Kit Capacitors Assortment Kit Inductor Assortment Kit Breadboard Set of connection wires BJP transistor, NPN type LM358 Op-Amp IC Potentiometer (2 kΩ) Resistor 470 Ω Capacitor 0.22 μF LED 100 Ω and 100 kΩ resistors DIP Switch Aluminum beam (2 mm x 15 mm x 1000 mm) Strain gauge G = 2, R = 120 Ω (and bonding adhesive) Potentiometer (200 kΩ max) Resistor 120 Ω Resistor 100 kΩ Resistor 1000 Ω On/Off (pull) type DC solenoid On/Off (push-pull) type DC solenoid Transistor: IRF510 (MOSFET) Diode EDE1200 IC (translator chip) Stepper Motor Potentiometer (200 Ω) ULN2003A - Transistor array IN4744 - Zener diode Resonator: AWCR 4.00 MD DC Motor Optoisolator IRF511 (MOSFET) IRF9520 (MOSFET) Opto-interrupter Disk with holes Arduino Board, shields & cables

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Quantity 1 1 1 1 1 set 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Part No. 81832 130232 388042 20722 20079 38359PS 23966 41865 107537 25540 119634 107465 38818 1663T12 SG-6/120LY11 SG401 241349 30082 107764 30081 142463 145314 06F8238 76970 141532 151861 181972 60K7049 36185 13J2002 154915 114083 39C4310 07B1521 273560 Constructed in lab 2151486

Supplier www.jameco.com www.jameco.com www.jameco.com www.jameco.com www.jameco.com www.jameco.com www.jameco.com www.jameco.com www.jameco.com www.jameco.com www.jameco.com www.jameco.com www.jameco.com McMaster www.omega.com www.omega.com www.jameco.com www.jameco.com www.jameco.com www.jameco.com www.jameco.com www.jameco.com www.newark.com www.jameco.com www.jameco.com www.jameco.com www.jameco.com www.newark.com www.jameco.com www.newark.com www.jameco.com www.jameco.com www.newark.com www.newark.com www.jameco.com A tick paper/plastic disk www.jameco.com

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Final Project: Digital PID Controller Implementation and HIL Testing using Arduino Microcontrollers Implement a digital PID control algorithm with programmable timer interrupt update time on one Arduino board using Matlab/Simulink environment as well as C language in IDE of Arduino. The digital PID algorithm is equivalent to analog PID controller built as part of Experiment 6. Implement a mass-force system dynamic model and its real-time simulation on another Arduino board. Designed and built I/O interface between the two Arduino boards using PWM output, ADC input and low-pass filter. Build a low pass active-filter using op-amps to convert the position variable, which is in PWM output form, of mass-force simulation into analog signal, and another low pass filter the PWM output of the PID controller to analog voltage. Simulate, test and document the operation of the closed loop control system: PID controller and mass-force system. Another version of this experiment uses CAN bus communication between the two Arduino boards to exchange I/O information, in which case PWM and ADC channels are not used and low pass filters are not needed. Each Arduino board is added with a CAN bus module. The PID controller output (control signal) is given a message ID number. The “plant model: mass-force” output is the simulated position signal and is given another message ID. Both Arduinos read/write from/to the CAN bus their respective messages at a programmable sampling rate. Plant model is further modified to represent a closed loop proportional valve controlled hydraulic system. The hydraulic system has one proportional valve which is the actuator and the input to it is the PID controller output signal. The hydraulic system consists of a pressure compensated variable displacement pump (inline, axial type), a proportional valve, one cylinder and fixed inertia load and line relief valve. Simulated cylinder position variable is fed-back to the PID controller. Electronic Hardware Skills: Digital Multimeter (DMM), Digital Oscilloscope, Function Generator, DC Power Supplies, Electronic Interface Circuits, Op-Amps. Software Skills: Matlab, Simulink (including auto-code generation, S-functions), Python, C/C++. Final Project: Due at the end of Final Exams Week.

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Objectives: Learn the microcontroller hardware, I/O channels, and interface circuits.

Learn basic hardware interface between a microcontroller, analog input devices and PWM output devices. Learn to develop real time control software, implement and test it on Arduino: PID control algorithm using Matlab/Simulink and the integrated development environment (IDE) software for Arduino UNO board. Learn to develop a hardware in the loop (HIL) simulation of a plant dynamics in real time using a second Arduino board. Learn to develop a HIL simulation of mass-force system dynamics. Interface the two Arduino boards, and test the whole system. Procedure: Install on your PC/Mac Matlab/Simulink Ardunio Support Package and test it. Documentation for this provided separately. Install on your PC/Mac Arduino IDE software development tool and test it. Documentation for this provided separately. The detailed PID control theory can be read from the lab manual (Lab 6 - Analog PID). There are two Arduino boards: Arduino board 1 is for PID control algorithm. U(t) = Kp * (xd(t) – x(t) ) + Ki * Integral(xd(t)-x(t)) + Kd * Derivative(xd(t)-x(t)) U(t)

= Kp * e(t) + Ki * Integral(e(t)) + Kd * Derivative(e(t))

where Kp, Ki, Kd are parameters. Ki * Integral(xd(t)-x(t)) term should be limited to plus/minus certain level of saturation. U(t) should be limited to plus/minus maximum value we can send out to PWM channel. -

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