22-Mec-B4 Integrated Manufacturing Systems · Undated paper
Question 6 of 7: Digital-to-Analog Conversion with a Zero-Order Hold
Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)
Notes on this paper
Paper format. National Examination
16-Mec-B4, Integrated Manufacturing Systems (the archive copy is filed
undated; the printed page header reads May 2019). Three hours, OPEN BOOK,
any non-communicating calculator permitted. Seven questions are
printed; any five constitute a complete paper and only the first five
appearing in the answer book are marked, so each question is worth 20 of the
100 marks and carries about 36 minutes. Some questions require an essay answer,
where clarity and organisation are themselves marked. All seven are worked
below, because the set as a whole is the study resource.
Reference texts for this subject.
Chase & Jacobs, Operations and Supply Chain Management, 16th ed.
— inventory models, break-even and capacity analysis.
Nahmias & Olsen, Production and Operations Analysis, 7th ed.
— the EOQ family and its variants.
Montgomery, Introduction to Statistical Quality Control, 8th ed.
— Shewhart charts, operating-characteristic curves and average run length.
Duncan, Quality Control and Industrial Statistics, 5th ed.
— the classical control-chart and inspection material these questions come from.
Groover, Automation, Production Systems, and Computer-Integrated
Manufacturing, 5th ed. — materials handling, and the data-acquisition
and conversion chapter behind Question 6.
Ebeling, An Introduction to Reliability and Maintainability
Engineering, 3rd ed. — series and active-redundant configurations.
Buffa & Sarin, Modern Production / Operations Management, 8th ed.
— plant layout and materials-handling systems.
Question 6: Digital-to-Analog Conversion with a Zero-Order Hold (20 marks)
Find. The analog voltage the converter puts out during the
sampling interval that follows instant $t$.
Output of the six-bit converter. A zero-order hold reproduces the sampled value as a staircase: the output steps to the value decoded at instant t and stays there, flat, until the next sample arrives.
Approach. Decode each register into the fraction of the
reference voltage it represents by weighting bit $k$ with $2^{-k}$, multiply by
the reference, and then apply the definition of a zero-order hold — the
output is held at the most recent sampled value, so it is a constant across the
interval.
State the converter output equation.
In a weighted-resistor or ladder DAC each register bit switches in a current
proportional to its place value, so with $B_1$ the most significant bit
$$E_{\text{out}} = E_{\text{ref}} \sum_{k=1}^{n} B_k\,2^{-k},$$
that is $E_{\text{ref}}$ times
$\left(0.5B_1 + 0.25B_2 + 0.125B_3 + 0.0625B_4 + 0.03125B_5 + 0.015625B_6\right)$,
taking the output amplifier gain as unity, which is the standard convention
unless a gain is stated.
Decode the register at instant $t$.
The contents are 1 0 1 1 0 1, so the non-zero weights are those of $B_1$, $B_3$,
$B_4$ and $B_6$:
$$\sum B_k 2^{-k} = 0.5 + 0.125 + 0.0625 + 0.015625 = 0.703125
= \frac{45}{64}.$$
Convert that fraction to a voltage.
$$E(t) = 10 \times 0.703125
= \boxed{E(t) = 7.03125\ \text{V.}}$$
Decode the previous instant, for the step size.
At $t-1$ the register held 1 0 1 0 1 0, giving
$0.5 + 0.125 + 0.03125 = 0.65625 = \tfrac{42}{64}$ and
$E(t-1) = 6.5625$ V. The output therefore steps up by
$$\Delta E = 7.03125 - 6.5625 = 0.46875\ \text{V}$$
at instant $t$ — three least-significant-bit counts, since the binary
count moved from 42 to 45.
Apply the zero-order hold.
A zero-order hold reconstructs a continuous signal by latching the most recent
sample and holding it unchanged until the next one arrives; its output is a
piecewise-constant staircase, and it uses no information about the rate of
change. Hence for the whole interval $t \le \theta < t + \tau$,
$$\boxed{E(\theta) = E(t) = 7.03125\ \text{V, constant for the full }
0.5\ \text{s interval.}}$$
The reading at $t-1$ therefore does not enter the answer; it is given so that
the step, and the contrast with a first-order hold, can be seen.
Quote the resolution, which bounds the accuracy of that value.
A six-bit register can express $2^{6} = 64$ levels, that is 63 steps between
zero and full scale, so
$$\text{resolution} = \frac{E_{\text{ref}}}{2^{n}-1} = \frac{10}{63}
= 0.1587\ \text{V per count,}$$
and the largest output the converter can produce is
$E_{\text{ref}}(1 - 2^{-6}) = 9.84375$ V, which falls short of the 10 V
reference by exactly one least-significant-bit weight of 0.15625 V. Every held
value therefore carries a quantisation uncertainty of about
$\pm 0.079$ V.
For comparison, a first-order hold would extrapolate at the slope implied by
the last two samples, $\alpha = \Delta E / \tau = 0.46875/0.5 = 0.9375$ V/s,
ramping from 7.03125 V to 7.5 V across the interval. That tracks a smoothly
varying signal more closely but overshoots badly at a reversal, which is why the
zero-order hold is the standard output stage of an industrial DAC and why this
question specifies it.
Final results.
Quantity
Result
Binary fraction at instant $t-1$ (101010)
0.65625 = 42/64
Output at instant $t-1$
6.5625 V
Binary fraction at instant $t$ (101101)
0.703125 = 45/64
Output during the interval following $t$ (zero-order hold)