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97 views102 pages

Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering (Instructor Solution Manual, Solutions) 7th Edition William Bolton Full Access

Complete syllabus material: Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering (Instructor Solution Manual, Solutions) 7th Edition William BoltonAvailable now. Covers essential areas of study with clarity, detail, and educational integrity.

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Instructor’s Manual
Mechatronics
Electronic Control Systems in
Mechanical and Electrical Engineering

Seventh edition

William Bolton

For further instructor material


please visit:

www.pearsoned.co.uk/bolton
ISBN: 978-1-292-25098-4

 Pearson Education Limited 2019


Lecturers adopting the main text are permitted to download and photocopy the manual as required.

Harlow, England • London • New York • Boston • San Francisco • Toronto • Sydney • Dubai • Singapore • Hong Kong
Tokyo • Seoul • Taipei • New Delhi • Cape Town • São Paulo • Mexico City • Madrid • Amsterdam • Munich • Paris • Milan
Pearson Education Limited
KAO Two
KAO Park
Harlow CM17 9NA
United Kingdom
Tel: +44 (0)1279 623623
Web: www.pearson.com/uk
-----------------------------------

Third edition published 2003


Fourth edition published 2008
Fifth edition published 2011
Sixth edition published 2015
This edition published 2019

© Pearson Education Limited 2019

The right of William Bolton to be identified as author of this work has been asserted by him in
accordance with the Copyright, Designs and Patents Act 1988.

Pearson Education is not responsible for the content of third-party internet sites.

ISBN 978-1-292-25098-4

All rights reserved. Permission is hereby given for the material in this publication to be
reproduced for OHP transparencies and student handouts, without express permission of the
Publishers, for educational purposes only. In all other cases, no part of this publication may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise without either the prior written permission of
the Publishers or a licence permitting restricted copying in the United Kingdom issued by the
Copyright Licensing Agency Ltd., Barnard’s Inn, 86 Fetter Lane, London EC4A 1EN. This book
may not be lent, resold, hired out or otherwise disposed of by way of trade in any form of binding
or cover other than that in which it is published, without the prior consent of the Publishers.

All trademarks used herein are the property of their respective owners. The use of any trademark
in this text does not vest in the author or publisher any trademark ownership rights in such
trademarks, nor does the use of such trademarks imply any affiliation with or endorsement of this
book by such owners.
Contents

Supporting notes for lecturers 4

Multiple-choice tests 12

Test 1: Sensors and signal conditioning 13

Test 2: Actuation 21

Test 3: System models 28

Test 4: Microprocessor systems 35

Supporting material: Electrical components and circuits 51

3
© Pearson Education Limited 2019
Instructor’s Guide

This manual includes:

1. Supporting notes for lecturers

2. Multiple-choice tests

3. Supporting material: Electrical components and circuits

Supporting notes for lecturers

About this resource manual

This resource manual is designed to support the seventh edition of the book Mechatronics by
indicating how the book might be used and providing multiple-choice tests.

About the book

The first edition was designed to cover the Business and Technology Education Council (BTEC)
Mechatronics units for Higher National Certificate/Diploma courses for technicians and designed
to fit alongside more specialist units such as those for design, manufacture and maintenance
determined by the application area of the course. The book was widely used for such courses and
has also found use in undergraduate courses in both Britain and in the United States. Following
feedback from lecturers in both Britain and the United States, the second edition was considerably
extended and with its extra depth it was not only still relevant for its original readership but also
suitable for undergraduate courses. The third edition involved refinements of some explanations,
more discussion of microcontrollers and programming, increased use of models for mechatronics
systems, and the grouping together of key facts in the Appendices. The fourth edition was a
complete reconsideration of all aspects of the text, both layout and content, with some regrouping
of topics, movement of more material into Appendices to avoid disrupting the flow of the text,
new material – in particular an introduction to artificial intelligence, more case studies and a
refinement of some topics to improve clarity. Also, objectives and key point summaries were
included with each chapter. The fifth edition kept the same structure but, after consultation with
many users of the book, many aspects have had extra detail and refinement added.

The sixth edition involved a restructuring of the constituent parts of the book as some users felt
that the chapter sequencing did not match the general teaching sequence. Other changes included
the inclusion of material on Arduino and the addition of more topics in the Mechatronics Systems
chapter. The seventh edition has continued the evolution of the book with updating of
mechatronics system components, clarification of some aspects so they read more easily, the
inclusion of information on the Atmega microcontrollers, a discussion and examples of fuzzy
logic and neural control systems and yet more applications and case studies. The number of
Appendices has been reduced as they had grown over previous editions and it was felt that some
were now little used. Appendix G Electrical circuit analysis has, with some extension, been moved
to this Instructor’s guide.

4
© Pearson Education Limited 2019
Bolton, Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering, 7e,
Instructor’s Manual

The overall aim of the book is to give a comprehensive coverage of mechatronics which can be
used with courses for both technicians and undergraduates in engineering, and hence, to help the
reader:

1. Acquire a mix of skills in mechanical engineering, electronics and computing which is


necessary if he/she is to be able to comprehend and design mechatronics systems.

2. Become capable of operating and communicating across the range of engineering


disciplines necessary in mechatronics.

3. Be capable of designing mechatronic systems.

Each chapter of the book includes objectives, a summary, is copiously illustrated and contains
problems, answers to which are supplied at the end of the book. With Chapter 24 research and
design assignments are also included, clues as to their possible answers also being given.

Order of work in the text

The book has been written so that a comprehensive coverage of mechatronics is given by starting
at Chapter 1 and working steadily through the chapters in the sequence given. The course structure
is then the topics of:

Part I Introduction

Chapter 1 is a general introduction to mechatronics.

Part II Sensors and signal conditioning

Chapters 2 to 6 form a coherent block on sensors and signal conditioning.

Part III Actuation

Chapters 7 to 9 cover actuators.

Part IV Microprocessor systems

Chapters 10 to 16 are concerned with microprocessor systems.

Part V System models

Chapters 17 to 23 are concerned with system models.

Part VI Conclusion

Chapter 24 provides an overall conclusion in considering the design of mechatronics systems.

The objectives of individual chapters

Chapter 1 Introducing Mechatronics

Explain what is meant by mechatronics and appreciate its relevance in engineering design.

5
© Pearson Education Limited 2019
Bolton, Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering, 7e,
Instructor’s Manual

Explain what is meant by a system and define the elements of measurement systems.

Describe the various forms and elements of open-loop and closed-loop systems.

Recognise the need for models of systems in order to predict their behaviour.

This chapter is a general introduction to the subject of mechatronics, touching on all the main
aspects involved in the design of such systems, these all being considered in more detail in the
rest of the book.

Chapter 2 Sensors and transducers

Describe the performance of commonly used sensors using terms such as range, span, error,
accuracy, sensitivity, hysteresis and non-linearity error, repeatability, stability, dead band,
resolution, output impedance, response time, time constant, rise time and settling time.

Evaluate sensors used in the measurement of displacement, position and proximity, velocity and
motion, force, fluid pressure, liquid flow, liquid level, temperature and light intensity.

Explain the problem of bouncing when mechanical switches are used for inputting data and how
it might be overcome.

This considers the terminology used to describe the performance of sensors and transducers and
then discusses the principles of commonly encountered sensors.

Chapter 3 Signal conditioning

Explain the requirements for signal conditioning.

Explain how operational amplifiers can be used.

Explain the requirements for protection and filtering.

Explain the principles of the Wheatstone bridge and, in particular, how it is used with strain
gauges.

Explain the principle of pulse modulation.

Explain the problems that can occur with ground loops and interference and suggest possible
solutions to these problems.

State the requirements for maximum power transfer between electrical components.

This chapter is a consideration of the main methods used in signal conditioning. In particular there
is a long section on the operational amplifier, this being drawn on considerably in later chapters.

Chapter 4 Digital signals

Explain the principles and main methods of analogue-to-digital and digital-to-analogue


converters.

Explain the principles and uses of multiplexers.

6
© Pearson Education Limited 2019
Bolton, Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering, 7e,
Instructor’s Manual

Explain the principles of digital signal processing.

This follows on from the previous chapter. An elementary introduction to digital signal processing
is included.

Chapter 5 Digital logic

Recognise the symbols for logic gates AND, OR, NOT, NAND, NOR and XOR, and use such
gates in applications., recognising the significance of logic families.

Explain how SR, JK and D flip-flops can be used in control systems.

Explain the operation of decoders and the 555 timer.

This chapter is a basic introduction to combinational and sequential digital logic. Appendix B:
Number Systems and Appendix C: Boolean algebra might be used in conjunction with this
chapter.

Chapter 6 Data presentation elements

Explain the problem of loading in measurement systems.

Identify commonly used data presentation elements and describe their characteristics.

Explain the principles of magnetic and optical recording.

Explain the principles of displays, in particular the LED seven-segment and dot matrix displays.

Describe the basic elements of data acquisition systems and data loggers.

This chapter is a basic introduction to the output presentation of data.

Chapter 7 Pneumatic and hydraulic actuation systems

Interpret system drawings and design simple systems, for sequential control systems involving
hydraulic/pneumatic directional control valves and cylinders.

Explain the principles of process control valves, their characteristics and sizing.

This chapter has essentially two main parts: a consideration of the use of directional control valves
in the design of sequential control systems and the use of process control valves in closed-loop
process control systems. The sequential control systems are picked up and further discussed in
later chapters.

Chapter 8 Mechanical actuating systems

Determine possible mechanical actuation systems for motion transmission involving liner-to-
rotary, rotary-to-rotary, rotary-to-linear and cyclic motion transmission.

Evaluate the capabilities of linkages, cams, gears, ratchet-and-pawl, belt and chain drives and
bearings for actuation systems.

7
© Pearson Education Limited 2019
Bolton, Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering, 7e,
Instructor’s Manual

This is a general overview of the main mechanical actuation elements. Linkage mechanisms and
cams features in design solutions in the final chapter of the text.

Chapter 9 Electrical actuation systems

Evaluate the operational characteristics of electrical actuation systems: relays, solid-state switches
(thyristors, bipolar transistors and MOSFETs), solenoids, d.c. motors, a.c. motors, steppers and
d.c. servo motors.

Explain the principles of d.c. motors, including the d.c. permanent magnet motor and how it can
have speed control.

Explain the principles of the brushless permanent magnet d.c. motor.

Explain the principles of the variable reluctance, permanent magnet, hybrid forms of stepper
motor and how step sequences can be generated, and the d.c. servo motor.

Explain the requirements in selecting motors of inertia matching and torque and power
requirements.

This is a key chapter in the discussion of actuators for use with microprocessor control systems,
in particular the control of motors, and is drawn on in many of the later chapters.

Chapter 10 Microprocessors and Microcontrollers

Describe the basic structure of a microprocessor system.

Describe the architecture of common microprocessors and how they can be incorporated in
microprocessor systems.

Describe the basic structure of microcontrollers and how their registers can be set to carry out
tasks.

Explain how programs can be developed using flow charts and pseudocode.

This chapter is a basic introduction to the structure of microprocessor and microcontroller systems
with examples of commonly encountered systems.

Chapter 11 Assembly language

Use assembly language to write programs involving data transfers, arithmetic, logic, jumps,
branches, subroutines, delays and look-up tables.

Where lecturers mainly use C, this chapter might just be given a cursory consideration.

Chapter 12 C language

Comprehend the main features of C programs.

Use C to write simple programs for microcontrollers.

Write programs for Arduino boards.

8
© Pearson Education Limited 2019
Bolton, Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering, 7e,
Instructor’s Manual

This is a basic general introduction to the use of C to write programs for microprocessor-based
systems.

Chapter 13 Input/output systems

Identify interface requirements and how they can be realised: buffers, handshaking, polling and
serial interfacing.

Explain how interrupts are used with microcontrollers.

Explain the functions of peripheral interface adapters and be able to program them for particular
situations.

Explain the function of asynchronous communication interface adapters.

This is a key chapter in the development of applications for microprocessor-based systems.

Chapter 14 Programmable logic controllers

Describe the basic structure of PLCs and their operation.

Develop ladder programs for a PLC involving logic functions, latching, internal relays and
sequencing.

Develop programs involving timers, counters, shift registers, master relays, jumps and data
handling.

This is a basic introduction to the use of PLCs and the writing of ladder programs. Where PLCs
are available, it can be usefully used to develop many assignments with students who otherwise
struggle with writing programs.

Chapter 15 Communication systems

Describe centralised, hierarchical and distributed control systems, network configurations and
methods of transmitting data and protocols used.

Describe the Open Systems Interconnection communication modes.

Describe commonly used communication interfaces: RS-232, IEEE 488, 20 mA current loop, I2C
bus and CAN.

This chapter is a discussion of methods used for the linking together of microprocessor-based
systems, computers and instruments.

Chapter 16 Fault finding

Recognise the techniques used to identify faults in microprocessor-based systems, including both
hardware and software.

Explain the use of emulation and simulation.

Explain how fault finding can be achieved with PLC systems.

9
© Pearson Education Limited 2019
Bolton, Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering, 7e,
Instructor’s Manual

This is a general discussion of fault finding for systems that might have been developed from
consideration of the earlier sections of this book and also arise in the following chapters.

Chapter 17 Basic system models

Explain the importance of models in predicting the behaviour of systems.

Devise models from basic building blocks for mechanical, electrical, fluid and thermal systems.

Recognise analogies between mechanical, electrical, fluid and thermal systems.

This chapter is the introduction to the group of chapters on system models and leads in later
chapters to indicating how differential equations can be developed for systems so that their
performance with time can be determined when they are subject to inputs.

Chapter 18 System models

Devise models for rotational-translational, electromechanical and hydraulic-mechanical systems.

Linearize non-linear relationships in order to generate linear models.

This extends chapter 10 to more complex systems.

Chapter 19 Dynamic responses of systems

Model dynamic systems by means of differential equations.

Determine the outputs of first-order systems to inputs and determine time constants.

Determine the outputs of second-order systems to inputs and identify the under-damped, critically
damped and over-damped conditions.

Describe the characteristics of second-order system responses in terms of rise time, overshoot,
subsidence ration, decrement and settling time.

This looks at the solution of the differential equations that have been devised for models and thus
how such systems will react when subject to various inputs.

Chapter 20 System transfer functions

Define the transfer function and determine it from differential equations for first- and second-
order systems.

Determine the transfer function for systems with feedback loops.

Determine, using Laplace transforms, the responses of first- and second-order systems to simple
inputs.

Determine the effect of pole location on the responses of systems.

This introduces the transfer function and the Laplace transform, Appendix A giving a more
detailed consideration.

10
© Pearson Education Limited 2019
Bolton, Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering, 7e,
Instructor’s Manual

Chapter 21 Frequency response

Explain the meaning of the frequency-response function.

Analyse the frequency response of systems subject to sinusoidal inputs.

Plot and interpret Bode plots.

Use Bode plots for system identification.

Explain the term bandwidth.

Explain how the gain margin and phase margin can be used to indicate the stability of a system.

Following an initial discussion of phasors, this chapter considers the frequency response of
systems.

Chapter 22 Closed-loop controllers

Explain the term steady-state error.

Explain the operation of the two-step mode of control.

Explain the behaviour of systems with proportional, integral, derivative, proportional plus
integral, proportional plus derivative and PID control.

Describe how digital controllers operate.

Explain how controllers can be tuned.

This is a key chapter in any discussion of closed-loop control. While the chapter has been written
as following the discussion of system models, it would be possible to use this chapter without
such a background.

Chapter 23 Artificial intelligence

Explain what is meant by an intelligent machine and the capabilities of such machines.

Explain the meaning of artificial neural networks and their relevance to pattern recognition.

Explain the term fuzzy logic and its applications in modern machines.

This chapter is a basic introduction to the subject of artificial intelligence.

Chapter 24 Mechatronic systems

Develop possibly solutions to design problems when considered from the mechatronics point of
view.

Describe the basic elements used in robotics.

11
© Pearson Education Limited 2019
Bolton, Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering, 7e,
Instructor’s Manual

Analyse case studies of mechatronic solutions.

This chapter is designed to draw together many of the principles discussed in earlier chapters and
lead to a consideration of mechatronic case studies and design assignments for students.

Multiple-choice tests

The following are multiple-choice tests, answers being given at the end of the tests. For the tests,
the chapters have been grouped to enable lecturers to be able to use the tests if different routes are
taken or blocks omitted. The tests are:

1. Sensors and signal conditioning

On Chapters 2, 3, 4 and 6

2. Actuation

On Chapters 7, 8 and 9

3. System models

On Chapters 17, 18, 19, 20, 21 and 22

4. Microprocessor systems

On Chapters 10, 11, 12, 13, 14, 15 and 16

12
© Pearson Education Limited 2019
TEST 1

Sensors and signal conditioning

For the following questions, you have four answer options A, B, C and D. Choose the correct
answer from the answer options.

1. A pressure sensor has a range of 0 to 1,000 kPa and a non-linearity error of ±0.15% of full
range and a hysteresis error of ±0.05% of full range. The error for a reading of 300 kPa is:
A ±0.3 kPa
B ±0.6 kPa
C ±1.0 kPa
D ±2.0 kPa

2. A sensor, for an input of 4 V, gives a digital output of a word of 8 bits. The resolution is:
A 4/8 V
B 8/4 V
C 4/28 V
D 28/4 V

3. Decide whether each of these statements is TRUE (T) or FALSE (F).


A sensor has a thermal sensitivity of 0.030% full range output /ºC and two ranges 50 to 1,000
kPa and 1,000 to 60,000 kPa. When there is a temperature change of 1ºC, the sensitivity
changes by:
(i) 0.3 kPa on the lower range.
(ii) 18 kPa on the upper range.
Which option BEST describes the two statements?
A (i) T (ii) T
B (i) T (ii) F
C (i) F (ii) T
D (i) F (ii) F

4. A thermocouple sensor has a time constant of 50 s in still air. When it is subject to a


temperature change of 100ºC, in 50 s its temperature will have changed by about:
A 31ºC
B 50ºC
C 63ºC
D 100ºC

13
© Pearson Education Limited 2019
Bolton, Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering, 7e,
Instructor’s Manual

5. A linear potentiometer of resistance 1 kΩ has a load of resistance 10 kΩ connected across it.


When the supply voltage across the potentiometer is 4 V and the potentiometer slider is at the
mid-point, there will be a non-linearity error due to loading of:
A 0.05 V
B 0.20 V
C 0.40 V
D 0.50 V

6. Absolute encoders are used to determine the angular position of a shaft and to avoid false
counting when the shaft rotates:
A Binary code is used.
B Gray code is used.
C BCD code is used.
D Hex code is used.

7. The change in resistance of an electrical resistance strain gauge with a gauge factor of 2.0 and
a resistance of 100 Ω when subject to a strain of 0.001 is:
A 0.05 Ω
B 0.1 Ω
C 0.2 Ω
D 2.0 Ω

8. A T-thermocouple, with a cold junction temperature of 0ºC, is to be used to measure


temperatures between 0 and 200ºC. Tables give the e.m.f. for a cold junction of 0ºC as 4.277
mV at 100ºC and 9.286 mV at 200ºC. If a linear relationship is assumed over the full range
for this sensor, the linearity error at 100ºC will be:
A −3.9ºC
B −7.9ºC
C +3.9ºC
D +7.9ºC

9. A thermocouple is used with a compensation circuit:


A Because the e.m.f. is not a linear function of temperature.
B To increase the time constant of the sensor.
C To amplify the small thermoelectric e.m.f.
D Because the cold junction is not held at 0ºC.

14
© Pearson Education Limited 2019
Bolton, Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering, 7e,
Instructor’s Manual

Questions 10 to 12 relate to the following information. The following are operational


amplifier circuits:

Select the operational amplifier circuit that will give the following outputs:

10. An output that is a linear function of the input.

11. An output that always has a voltage gain of 1.

12. An output that is proportional to the integral of the input voltage.

13. For the operational amplifier circuit shown in the following figure:

The output is:


A Three times the sum of V1 and V2.
B Three times the difference between V1 and V2.
C Twice the sum of V1 and V2.
D Twice the difference between V1 and V2.

15
© Pearson Education Limited 2019
Bolton, Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering, 7e,
Instructor’s Manual

14. The operational amplifier circuit shown in the following figure includes a thermistor.

The relay must be activated when the thermistor resistance is:


A Less than 100 Ω.
B 200 Ω.
C Between 100 and 300 Ω.
D More than 300 Ω.

15. Decide whether each of these statements is TRUE (T) or FALSE (F).
The Wheatstone bridge shown in the following figure is balanced when there is no load on
the load cell.

When the load is applied to the load cell:


(i) R1 increases.
(ii) The potential at A is greater than that at B.
Which option BEST describes the two statements?
A (i) T (ii) T
B (i) T (ii) F
C (i) F (ii) T
D (i) F (ii) F

16
© Pearson Education Limited 2019
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