The Egyptian Chinese University Mechatronics Engineering

Electronics Instrumentation

 Dr.Mohamed A. Shamseldin
 Electronics and Instrumentation
 Instructor: Dr.Mohamed Abdelbar
 e-mail : mabdelbarr@ecu.edu.eg
 Office Hours: 9:00 – 11:00 (Wednesday),

 T.A.: Eng. Ahmed Assal

 Lecture: 8:30 pm -- 10:30 pm (Monday)

 Textbook:
D.G. Alciatore, M.B. Histand, “Introduction to Mechatronics and
Measurement System”, McGraw Hill, 2003, 2007.

 Other References:
Bolton, William; “ Mechatronics: Electronic Control
Systems in Mechanical and Electrical Engineering”;
Prentice Hall, 2003.
OVERALL AIMS & OUTCOMES OF COURSE:
This course addresses an introduction to Mechatronics specialization in general and
the concept of Multidisciplinary and synergistic integration of different engineering
areas.
After completion of this course the student should have the knowledge and skills
that enable her/ him to:

1. Use the available software for designing, analyzing, and testing of Mechatronics
System.
2. Analyze, design, and or select the suitable signal conditioning circuit(s) for a
given Mechatronics system.
3. Be acquainted with data acquisition systems.
4. Work in a team through implementing a simple Mechatronics project.
5. Gain knowledge and experience through self-learning.
Elements of Mechatronics
 INPUT
• MECHANICAL SYSTEM SIGNAL
• SYSTEM MODEL CONDITIONI
NG AND
• DYNAMIC RESPORSE INTERFACING
ACTUATORS SENSORS • Discrete circuits.
• DC Motor. • Proximity. • Filters.
• Servo Motor. • Switches. • Amplifiers.
• Stepper Motor. • Potentiometers.
• Solenoid , voice • Photo electrics. • A/D,D/D.
coils. • Digital encoder.
• Hydraulics • Strain gage.
,pneumatics

DIGITAL
OUTPUT CONTROL
SIGNAL
ODITIONING
GRAPHICAL AND • Microcontroller.
DISPLAY INTERFACING • Sequencing and
timing.
• LCD. • Amplifiers.
• PWM.
• Logic circuits.
• CRT.
• Relays. • PLC.
• LEDS.
• Digital displays. • D/A ,D/D.
 Measurement Characteristics
 Range: Difference between the maximum and minimum value
of the sensed parameter
 Resolution: The smallest change the sensor can differentiate

 Accuracy: Difference between the measured value and the true

value
 Precision: Ability to reproduce the results repeatedly with a
given accuracy
 Sensitivity: Ratio of change in output to a unit change of the
input
 Zero offset: A nonzero value output for no input
 Measurement Characteristics

 Linearity: Percentage of deviation from the best-fit linear

calibration curve
 Zero Drift: The departure of output from zero value over a
period of time for no input
 Response time: The time lag between the input and output

 Operating temperature: The range in which the sensor

performs as specified
 Deadband: The range of input for which there is no output
 Range & Resolution
 Range: The range (or span) of a sensor is the difference between the
minimum (or most negative) and maximum inputs that will give a
valid output. Range is typically specified by the manufacturer of the
sensor.
 For example, a common type K thermocouple has a range of
800°C (from −50°C to 750°C).
 Resolution: The resolution of a sensor is the smallest increment of
input that can be reliably detected. Resolution is also frequently
known as the least count of the sensor.
 The resolution of analog sensors is usually limited only by low-
level electrical noise and is often much better than equivalent
digital sensors.
 Sensitivity
 Sensor sensitivity is defined
as the change in output per
unit change in input.

 The sensitivity of digital

sensors is closely related to
the resolution.

 The sensitivity of an analog

sensor is the slope of the
output versus input line.

 Linear & nonlinear behavior

 Error
 Error is the difference between a measured value and the true input
value.
 Two types of errors:
 Bias (or systematic) errors and
 Precision (or random) errors.
 Bias errors can be further subdivided into
 Calibration errors (a zero or null point error is a common type of
bias error created by a nonzero output value when the input is
zero),
 Loading errors (adding the sensor to the measured system changes
the system),
 errors due to sensor sensitivity to variables other than the desired
one (e.g., temperature effects on strain gages).
 Repeatability & Reproducibility

 A measurement system must first be accurate, precise &

repeatable before it can be reproducible.

 Repeatability refers to a sensor’s ability to give identical outputs

for the same input

 Precision (or random) errors cause a lack of repeatability

Accuracy, Precision & Repeatability
 Saturation, Dead-Band

 Saturation: All real actuators have some maximum output

capability, regardless of the input.
Comparison between Un-saturated & Saturdated Signal
2

1.5

1 Desired Output
0.5
Saturated Output
F o rc e in N e w t o n

-0.5

-1

-1.5

-2
0 1 2 3 4 5 6 7 8 9 10
Time in Seconds

 Deadband: The dead band is typically a region of input close to

zero at which the output remains zero. Once the input travels
outside the dead band, then the output varies with input.
Basic Principle of Sensor / Transduction

Measuring Conversion Device Useful Signal

Parameter

Displacement, Voltage, current,

Temperature, capacitance
Pressure etc….
Sensor is a device that when exposed to a physical phenomenon
(temperature, displacement, force, etc.) produces a proportional output signal
(electrical, mechanical, magnetic, etc.).

Transducer is a device that converts one form of (energy) signal into another
form of (energy) signal.
 Sensors

 Position Sensors:

 Potentiometer

 LVDT

 Encoders
 Potentiometer
 A rotary potentiometer is a variable resistance device that can
be used to measure angular position
 Through voltage division the change in resistance can be used
to create an output voltage that is directly proportional to the
input displacement.
Potentiometer
Linear Variable Differential Transformer
 ‘LVDT’ is a transducer for measuring linear displacement
 It must be excited by an AC signal to induce AC response on
secondary.
 The core position can be determined by measuring secondary
response.
Linear Variable Differential Transformer
 Encoders

 Digital Optical Encoders

 Absolute Digital Optical Encoders

 Incremental Digital Optical Encoders

 Digital Optical Encoders

Schematic Diagram

Typical Construction
Simple Rotary Encoder
Quadrature Encoder
Binary Encoder
Grey Code Encoder
Absolute Encoder
Absolute Encoder (Gray Code)
Incremental Encoder
 Proximity sensors

 Proximity sensors:

 Optical

 Inductive

 Capacitive
Proximity sensors
Application of Proximity sensors
 Inductive Proximity sensors
• Detects metal object
• Uses an electro-magnetic field to detect a conductive target
• Sensing coil in the end of the sensor probe
• When excited creates an alternating magnetic field which induces small
amounts of eddy current in the target object
• Eddy currents create an opposing magnetic field which resists the field
being generated by the sensor probe coil.
• The interaction of the magnetic fields is dependent on the distance
between the sensor probe and the target.
• Comparatively inexpensive but conducting targets sensing
Inductive Proximity sensors
 Capacitive Proximity sensors
 The sensing surface of the sensor’s probe is the electrified plate.
 The sensor electronics continually changes the voltage on the probe
surface
 The amount of current required change this voltage is measured
which indicates the amount of capacitance distance between the
probe and target.
 Can be used for nonmetallic materials such as paper, glass, liquids,
and cloth
Capacitive Proximity sensors
• Motion Sensors:

• Variable Reluctance

• Temperature Sensor:

• RTD

• Thermocouples
 Variable Reluctance sensor
 A magnet in the sensor creates a
magnetic field

 As a ferrous object moves by the

sensor, the resulting change in the
magnetic flux induces an emf in
the pickup coil
 Variable Reluctance sensor

• Used to measure speed and/or position of a moving metallic

object

• Sense the change of magnetic reluctance (analogous to

electrical resistance) near the sensing element

• Require conditioning circuitry to yield a useful signal (e.g.

LM1815 from National Semi.)
 Temperature measurement

• EMF based

• Thermocouple

• Resistance based

• Resistance Temperature Detectors (RTD)

 Thermocouples

 If two different metals ‘A’ and ‘B’ are connected as in Figure,

with a junction and a voltmeter, then if the junction is heated the
meter should show a voltage.

 This is known as the Seebeck effect.

 Construction of Thermocouples
 At the tip of a grounded junction probe, the thermocouple wires are
physically attached to the inside of the probe wall. This results in good heat
transfer from the outside, through the probe wall to the thermocouple
junction.
 In an ungrounded probe, the thermocouple junction is detached from the
probe wall. Response time is slower than the grounded style, but the
ungrounded offers electrical isolation.
 The thermocouple in the exposed junction style protrudes out of the tip of
the sheath and is exposed to the surrounding environment. This type offers
the best response time, but is limited in use to dry, non-corrosive and non-
pressurized applications.
 Types of thermocouples
Sr. Type Thermocouple Material Sensitivit Useful
No y in temperature
(µV/oC) range
1 T Copper-Constantan 20 – 60 -180 to +400
2 J Iron-Constantan 45 – 55 -180 to +850
3 K Chromel-Alumel 40 – 55 -200 to +1300
4 E Chromel-Constantan 55 – 80 -180 to +850
5 S Platinum-Platinum/10% Rhodium 5 – 12 0 to +1400
6 R Platinum-Platinum/13% Rhodium 5 – 12 0 to +1600
7 B Platinum/ 30% Rhodium-Platinum/6% Rhodium 5 – 12 +100 to +1800
8 W5 Tungsten/5% Rhenium-Tungsten/20% Rhenium 5 – 12 0 to +3000

Constantan = copper/nickel; Chromel = nickel/chromium; Alumenl = nickel/aluminium

 Selection of Thermocouples

The following criteria are used in selecting a thermocouple:

 Temperature range

 Chemical resistance of the thermocouple or sheath material

 Abrasion and vibration resistance

 Installation requirements (may need to be compatible with

existing equipment; existing holes may determine probe

diameter)
 Resistance Temperature Detector
(RTD)
Uses the phenomenon that the resistance of a metal changes with
temperature.
Are linear over a wide range and most stable.
Advantages of platinum as RTD
 The temperature-resistance characteristics of pure platinum
are stable over a wide range of temperatures.
 It has high resistance to chemical attack and contamination
 It forms the most easily reproducible type of temperature
transducer with a high degree of accuracy .
 It can have accuracy ± 0.01 oC up to 500 oC and ± 0.1 oC
up to 1200 oC.
Limitations of RTD
 These are resistive devices, and accordingly they function by
passing a current through a sensor.
 Even though only a very small current is generally employed,
it creates a certain amount of heat and thus can throw off the
temperature reading.
 This self heating in resistive sensors can be significant when
dealing with a still fluid (i.e., one that is neither flowing nor
agitated), because there is less carry-off of the heat
generated.
 This problem does not arise with thermocouples, which are
essentially zero-current devices.
Comparison: Thermocouple vs RTD