Reference no: EM132840895

Unit 06 Mechatronics - Pearson Higher Nationals in Engineering

Learning Outcome 1: Design a mechatronic system specification for a given application.

Learning Outcome 2: Examine the operation and function of a mechatronics system using simulation and modelling software

Learning Outcome 3: Identify and correct faults in a mechatronic system

Scenario:

You are part of a mechatronic design team that is required to modernize a manually controlled gantry crane to a PLC based mechatronic gantry crane that can select parts off a line based on their height requirements. To fully understand your task, you must analyse the desired operation of the crane and come up with the required design specification; see crane operation. You have been assigned the task of programming the x-axis control system for the crane.

Crane operation:

• Start-up conditions (Up limit SW closed, part detector ON)
• Once the start-up conditions are met, after turned on via (START/STOP SW) the crane begins its scan sequence (X- Axis motor ON, Left and Right Limit switches determine direction).
• When a part of the desired height is detected via the height detection sensor, the X- Axis motor stops, and the Y -Axis motors are enabled.
• The magnet is energized, and the crane arm is lowed until the lower limit SW is contacted.
• The crane then returns to its maximum height at its upper limit SW.
• The X-Axis motor is enabled and moves towards the left to deliver the part to the bin.
• The crane stops when it contacts the left limit switch and lowers the part into the bin.
• The magnet is de-energized at the lower limit switch, releasing the part into the bin.
• The crane then returns to its maximum height and begins to scan again, once the start-up conditions are met.

Q1 Using Zeilo-Soft to create and simulate a controls system model, produce a design specification, and simulate a fully documented control model for the x-axis control, in accordance with systems specifications of a PLC controlled mechatronic crane with part detection.
Your model will allow the crane to choose iron parts based on their height dimension and remove defective parts.
Your control modelled will be uploaded to the device (crane), to observe its functionality.

Note : (An overview of the system, will be carried out in class, so that you can select the appropriate sensors and actuators)
The systems specification headings are as follows:
Systems specifications headings:
British and/or European standards relevant to application.
Sensor types and interfacing. Actuator technology availability and selection. Selection and use of appropriate control software/devices.
Consideration of the interaction of system variables. System commissioning parameters.

Before designing/programming, select and justify the required sensors and actuators required for the system. For each sensor chosen you are to also provide at least one alternative that you would have considered in your selection. (utilize the table 1 as a guide)

Q2 Explain the function and operation of the simulated mechatronic crane/arm with part detection system. You are to provide a rung by rung explanation of your PLC program to clarify your program's functionality.

Q3 After simulating the system, you designed in Q1 Evaluate the operational capabilities and limitations of the mechatronics system design based on the specifications. This can be done by comparing what the intended function of your design of the mechatronic crane was and explaining what it cannot do "limitations" based on the type of sensors used, the way it interacts with system variables, and the control software.

Q4 Scenario:
The Mechatronic crane has been put into commission in a sand-casting factory. Within 6-months of service, the mechatronic crane has encountered an intermittent problem. When it arrives at its left limit, it intermittently jams against the switch but the X-Axis (left - right) motor does not stop, thus not completing its part scan or not delivering the part to the bin.
Your company has advised you to remotely assist the customer to rectify the issue.

i) Being a PLC based system, document all the suitable fault-finding techniques / methods which you used to deduce the problem, by utilizing a flow chart. The flow chart will show your fault- finding thought process and the possible solutions to the problem.

ii) Highlight and justify the most probable cause from your flow chart.

iii) Utilize your flow chart, to recommend the appropriate tests that can be used to find the fault.

iv) To fully justify your answer, include the following:
• A brief description of the steps taken to solve the problem.
• The identification of the required fault-finding equipment.
• An explanation for the safe/appropriate use of the fault-finding equipment.

Q5 Investigate the problem for the scenario in Q4, suggest an alternative method of improving safety and reliability to the PLC based mechatronic system design specification. Implement your solution into your PLC program from Q1 and explain its function.
Note: feel free to utilize, alarms, warning lights etc..
Q6 Pertaining to the mechatronic system in Q1, describe the advantages and disadvantages of the software simulation.

Attachment:- Mechatronics.rar