Intro to mechatronics

ME407
MECHATRONICS
SUKESH O P
Assistant Professor
Dept. of Mechanical
Engineering
JECC
10/16/18
1SUKESH O P/ APME/ME407- MR-2018

ME407 MECHATRONICS
 Course Objectives:
To introduce the features of various sensors
used in CNC machines and robots
To study the fabrication and functioning of
MEMS pressure and inertial sensors
To enable development of hydraulic/pneumatic
circuit and PLC programs for simple
applications
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SUKESH O P/ APME/ME407- MR-2018

Expected outcome:
The stude nts willbe able to
i. Know the mechanical systems used in
mechatronics ii. Integrate mechanical,
electronics, control and computer engineering
in the design of mechatronics systems
ME407 MECHATRONICS
10/16/18
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Expected outcome:
The stude nts willbe able to
i. Know the mechanical systems used in
mechatronics ii. Integrate mechanical,
electronics, control and computer engineering
in the design of mechatronics systems
ME407 MECHATRONICS
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SYLLABUS
 Introduction to Mechatronics, sensors,
Actuators, Micro Electro Mechanical Systems
(MEMS), Mechatronics in Computer Numerical
Control (CNC) machines, Mechatronics in
Robotics-Electrical drives, Force and tactile
sensors, Image processing techniques, Case
studies of Mechatronics systems.
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MODULE-I
 Introduction to Mechatronics: Structure of
Mechatronics system. Sensors -
Characteristics -Temperature, flow, pressure
sensors. Displacement, position and proximity
sensing by magnetic, optical, ultrasonic,
inductive, capacitive and eddy current
methods. Encoders: incremental and absolute,
gray coded encoder. Resolvers and synchros.
Piezoelectric sensors. Acoustic Emission
sensors. Principle and types of vibration
sensors. 10/16/18
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MODULE-1
Introduction to Mechatronics : Structure of
Mechatronics system.
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Introduction to Mechatronics
 The term “Mechatronics" was first assigned
by Mr. Tetsuro Mori, a senior engineer of the
Japanese company Yaskawa, in 1969.
 The word "mechatronics" was registered
as trademark by the company in Japan with
the registration number of "46-32714" in 1971.

Mechatronics
 Mechatronics is a multidisciplinary field of
science that includes a combination
of m e chanical e ng ine e ring , e le ctro nics,
co m pute r e ng ine e ring , te le co m m unicatio ns
e ng ine e ring , syste m s e ng ine e ring and co ntro l
e ng ine e ring .
 It specifically refers to multidisciplinary
approach to product and Manufacturing system
design.
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Mechatronics - de finitio n
 Mechatronics basically refers to mechanical
electronic systems and normally described as a
synergistic integration of mechanical engineering,
electronics andintelligent computercontrol indesign
andmanufactureof products andprocesses.
 In other words : synergistic integration of
mechanical engineering, electronic engineering,
computer technology and control engineering in
development of electromechanical products, through
anintegrateddesignapproach.
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Synergistic – means various parts

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Mechatronics
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systems
Advantages of Mechatronics systems
Cost effective and Very good quality.
High degree of flexibility.
Greater productivity.
Higher quantity and producing reliability.
Greater extent of machine utilisation.
Maintenance cost is less.
Machining of complex designs can be done.
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systems
Disadvantages of Mechatronics systems
High initial cost.
Skilled worker is required.
Fault detection s complex.
Complicated design and system
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systems
Features/Characteristics of Mechatronics
systems
High quality product.
High reliability and Safety.
Low coast.
Portable.
Produced quickly.
Serviceability, maintainability and upgradability.
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systems
Applications of Mechatronics systems
Automotives.
Flexible manufacturing systems(FMS).
Measurement systems.
Cd/DVD and setup boxes.
Robots employed in inspection and welding
operations.
Scanners/photocopier/fax .
Automatic washing machines.
Air conditioners, elevator controls.
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SUKESHOP/APME/ME407-MR-2018

systems
Scope of Mechatronics systems
Better design of products.
Better process planning.
Reliable and quality oriented manufacturing.
Intelligent process and production control.
Manufacturing of complex parts.
More Accurate and more precision of jobs.
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Components of a Mechatronics system
18
Structure of a Mechatronics system
Electrical systems
Controllers
10/16/18SUKESH O P/ APME/ME407- MR-2018

Components of a Mechatronics system
1. Actuators: Pro duce m o tio n o r cause so m e actio n. DC
motor, Stepper motors, servomotors, hydraulics,
pneumatics
2. Sensors: de te ct the state o f the syste m param e te rs,
inputs and o utputs. Switches, Potentiometer, Strain
gauge, Thermocouple, digital encoder
3. Input signal conditioning and interfacing: pro vide
co nne ctio n b/w the co ntro l circuits and the I/P Discrete
circuits, Amplifiers, Filters, A/D,D/D
4. Digital control architectures: Co ntro l the syste m . Logic
circuits, microcontroller, PLC
5. Output signal conditioning and interfacing : pro vide
co nne ctio n b/w the co ntro lcircuits and the O /P
D/A, D/D, Amplifiers, Power transisters.
6. Graphical Display : Pro vide visual fe e dback to
use rs. LEDs, Digital displays, LCD, CRT 10/16/18
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Modules In Mechatronic system
 IM – Interface Module
 ASM – Assembly Module
 PM- Processor Module.
 EM- Environment Module
 CM- Communication Module
 MM- Measurement Module
 AM- Actuation Module
 SM- Software Module
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Environment moduleEnvironment module
This module is concerned with the parameter
like forces, temperature, speed and their effect on
boundary of the system. This also deals with the
dynamics and existence of the system and the
function.
Assembly ModuleAssembly Module
Manufacturing mechanical and structural realization,
part and system integration are the activities in this
module. Input information is received from actuation
module and output is given to measurement
module.
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Measurement ModuleMeasurement Module
Sensors and micro devices, transducers are
the some components of this module, which supply
information output to communication module.
Gathers information about system status.
Actuation ModuleActuation Module
Hydraulic , pneumatic and electric actuators,
piezo-electric devices, microcontrollers are the
systems identified few in this module. This module
recieves information from the communication
module for execution. 10/16/18
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Communication ModuleCommunication Module
this is concerned with transmission of
information b/w modules within the system. The
input and output information's reveal the nature of
signal and distance over which it has to be
transmitted and operating environment. This module
mainly interacts with the processor module.
Processor ModuleProcessor Module
This is formed by micro processors, embedded and
electronic circuits. This extracts information from
communication module about measurement
parameters, demand settings system parameters to
be processed. This module interacts with interface
module and the software module for information
processing.
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Software ModuleSoftware Module
this module contains instructions for opening,
defined algorithms, operation control programs of
processor module. The nature and forms of
instruction are linked to associate and interact with
procesor module.
Interface ModuleInterface Module
Between various levels in the system, are
interfaced for transfer of information with interaction
with processor module and the system representing
the world. This provides man-machine interface for
user information. The information is classified by
nature od i/p x o/p. 10/16/18
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Levels of mechatronics system
1. Stand-alone systems, for ex: washing machine,
compact disk player, auto focus camera, boat
auto pilot, etc.
2. Systems with high level of distributed Sensor-
microcontroller-relationships, for ex: wire aircraft.
3. A large factory system that is also a distributed
system but which links a number of major
subsystems such as machining centers, robots
for part handling, automated inspection stations
etc,
4. A system that incorporates intelligent control or
artificial intelligence, for ex: humanoid robot.
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System
26
 System is a group of physical components
combined to perform a specific function. All
mechatronics devices consist of systems. A
system can be considered as a box that has
an input and an output.
 A control system can be considered as a
device that is used to control the output of the
system to a desired value.
Ex: domestic air-conditioning

System
27
Electric Generator
OutputInput
Mechanical
rotation
Electric power

Measurement systemsMeasurement systems
28
Digital Tachometer
OutputInput
Rotation of a
shaft
Number on the
LED display

Introduction to MeasurementIntroduction to Measurement
systemssystems
29
Elements of measuring system
1 . Transduce r : is a se nsing that co nve rts a
physicalinput into o utput, usually vo ltag e .
2. Sig nalpro ce sso r: pe rfo rm s filte ring and
am plificatio n functio ns.
3. Re co rde r: re co rds o r displays the o utput o f
sig nalpro ce sso r.
Transducer
Signal
Processor Recorder

Functions of Instruments and MeasurementFunctions of Instruments and Measurement
systemssystems
30
1.1. Indicating function:Indicating function: Exam ple s :- (1) A pressure
gauge is used for indicating pressure. (2) The
deflection of a pointer of a speedometer
indicates the speed of the automotive at that
moment.
2.2. Recording functionRecording function: Exam ple s :- (1) A
potentiometer type of recorder used for
monitoring temperature records the
instantaneous values of temperatures on a
strip chart recorder.
3.3. Controlling function:Controlling function: This is one of the most
important functions specially in the field of

Applications of MeasurementApplications of Measurement
SystemsSystems
31
1. Monitoring of processes and operations:1. Monitoring of processes and operations:
Example : (1) A voltmeter indicates the value of
current or voltage being monitored(measured) at a
particular instant. (2)Water and electric energy
meters.
2. Control of processes and operation:2. Control of processes and operation:
Example : (1) Typical refrigeration system which
employs a thermostatic control.
(2) A temperature measuring device senses the
room temperature thus providing the information
necessary for proper functioning of the control

Applications of MeasurementApplications of Measurement
SystemsSystems
32
3. Experimental engineering analysis:3. Experimental engineering analysis:
(1)Determination of system parameters, variables
and performance indices.
(2)Testing the validity of theoretical predictions.
(3)Solutions of mathematical relationships with
the help of analogies.

Measurement systemMeasurement system
performanceperformance
33
1. Static characteristics
a. Accuracy b. sensitivity
c. Reproducibility d. Static error.
2. Dynamic characteristics
a. speed of response b. Measuring lag.
c. Fidelity d. Dynamic error

Control systemsControl systems
34
 A co ntro l syste m is an arrang e m e nt o f
physical co m po ne nts co nne cte d o r re late d in
such a m anne r as to co m m and, dire ct o r
re g ulate itse lf o r ano the r syste m .
The basic functions of control systems are:
- to m inim iz e the e rro r b/w the actual and the
de sire d o utput.
- to m inim iz e the tim e re spo nse to lo ad
chang e s in the syste m .

Requirements of a controlRequirements of a control
systemsystem
35
1. Stability : for any change in the input signal,
the output of the system reads or makes its
response at reasonable value.
2. Accuracy : the closeness of the measured
value to the true value is known as accuracy.
3. Response : the quickness with which an
instrument responds to a change in the
output signal is known us response.

Examples of control systemExamples of control system
applicationsapplications
36
1. Steering control of automobile.
2. Printwheel control system.
3. Industrial sewing machines.
4. Sun-tracking control of solar collectors.
5. Speed control systems.
6. Temperature control of an electric furnace.

Elements of a control systemElements of a control system
37
1. Control variable
The quantity or condition of the controlled
system which can be directly measured and
controlled is called Co ntro lle d variable .
2. Indirectly controlled variable
The quantity or condition related to
controlled variable, but cannot be directly
measured is called Indire ctly co ntro lle d variable

Elements of a control systemElements of a control system
38
3. Command :3. Command : The input which can be
independently varied is called Co m m and.
4. Reference input:4. Reference input: A standard signal used for
comparison in the close-loop system.
5. Actuating signal:5. Actuating signal: The difference between the
feedback signal is called Actuating sig nal
6. Disturbance:6. Disturbance: Any signal other than the reference
which affects the system performance is called
disturbance .
7. System error:7. System error: The difference between the actual
value and ideal value is called Syste m e rro r.

Types of Control SystemsTypes of Control Systems
39
1. Open-loop control systems
o r
Non-feedback control systems.
2. Closed-loop control systems
o r
Feedback control systems.

Open-loop Control SystemsOpen-loop Control Systems
40

Advantages and Disadvantages of OLS
41 ADV:
Simple construction.
Easy maintenance.
Less cost.
Has better reliability and stability.
LIMITATIONS
Presence of non-linearities causes
malfunctioning.
The error cannot be corrected.
The control action depends upon input
command.
Its not suitable for rough works.

Closed-loop Control SystemsClosed-loop Control Systems
42

Advantages and Disadvantages of
CLS
43
ADV
More accurate
Control action basically depends upon feedback.
Change in system component is automaticaly
taken care of.
DISADV:
The system is complicated and expensive.
The system may become unstable.

Some examples:
Washing machine
The electric switch
Microwave oven
Air conditioner
Liquid level control
Feedforward
control system
Feedback
control system
10/16/1844 SUKESH O P/ APME/ME407- MR-2018

1. Less accurate
2. Generally build easily
3. Stability can be
ensured.
4. The control adjustment
depends upon human
judgment and estimate.
5. Any change is system
component cannot be
taken care of
automatically.
1. More accurate.
2. Generally complicated
and costly
3. May become unstable
at times.
4. The control adjustment
depends on output and
feedback element.
5. Change in system
component is
automatically taken
care of.
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Open-loop Closed-loop

Feed back principleFeed back principle
46
 The required level of control in open-loop
systems depends only on human judgment.
So, the performance of a control system can
be improved by upgrading the skill of the
operator and the nature of the measurement.
Only with experience is one able to predict the
results obtained.
 Ex: Ironbox

Basic elements of a FeedbackBasic elements of a Feedback
SystemSystem
47
1. Forward path:1. Forward path: The fo rward path co nsist o f
1.1. Error-detecting device:Error-detecting device: it is a device that
receives the output signal and compares it with
a standard value. It also gives the command o/p
signal at each &every instant.
2.2. Amplifier :Amplifier : it amplifies the o/p signal to a
suitable/ required scale.
3.3. Compensating network:Compensating network: it improves the overall
performance of the system.

Basic elements of a Feedback
System
48
2. Feedback system: This is the path that sends
the information about the o/p signal at each and
every instant to the error-detecting device.

Classification of feedback controlClassification of feedback control
systemssystems
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1. Regulatory systems.
2. Follow-up system.
3. Servo-mechanism systems.
4. Continuous data feedback systems.
5. Sampled or discrete data control systems.

Classification of feedbackcontrol
systems
50
1. Regulatory systems:1. Regulatory systems: this feedback control
system is used when the input signal is
constant, for ex: Refrigerator, Iron box
2. Follow-up system:2. Follow-up system: this feedback control
system is used when the input signal changes at
each and every instant and where the output
follows the input signal closely, Ex: Cam and
follower mechanism
3. Servo mechanism system:3. Servo mechanism system: This feedback
control system is used where the mechanical
quantity output with time derivatives is used.

Classification of feedback controlClassification of feedback control
systemssystems
51
4. Continuous data feedback systems:4. Continuous data feedback systems: This
feedback control system is used where the input
signal has functions of the continuous time
variable.
Ex: Potentiometers.
5. Sampled or discrete data control systems:5. Sampled or discrete data control systems:
This feedback control system is mainly used in
input signals that have pulses or have numerical
codes.
Ex: A/D converter and Digital to Analog(D/A)
converter.

Intro to mechatronics

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