This document provides an overview of actuators and mechatronic system design. It defines actuation as the conversion of any form of energy into mechanical form. The device that performs this conversion is called an actuator. Various types of actuators are classified, including electrical, mechanical, hydraulic/pneumatic, and active material-based actuators. Common actuators like motors, solenoids, and piezoelectric materials are described. The document also discusses concepts like mechatronic design approaches, case studies of various mechatronic systems, and the differences between traditional and mechatronic design methods.

1. Unit 5
Actuators and Mechatronic system
design

2. Actuate
• Cause (someone) to act
in a particular way;
motivate.

3. Actuate
• Cause (a machine or device) to operate.

4. Mechatronics System

5. Actuation & Actuator
• Conversion of any form of energy in to
Mechanical form is Actuation.
• The device doing this conversion is called as
Actuator.

6. Classification of Actuators
Actuator
Electrical
Actuator
> ON OFF type control
action
> Diodes, TRIACs,
Relays, Transistor
Electrical
Mechanical
Actuator
Motors
Electrical
Magnetic
Actuator
 Motion due to
internal magnetic
field
 Solenoid
Hydraulic &
Pneumatic
Actuator
Active
Material
based
Actuator
 Material undergo transformation
through Physical interactions
 Piezoelectric materials (small motion)
 Shape memory alloy (Nitinol)
 Magnetoastricive (Ferromagnetic
material change shape during
magnetism – Terfenol – Tb, Dy, Fe)
 Electro Rheological – change in
viscosity – Liquid to gell

12. Faraday’s Law of Induction

13. Electric Motors

14. Principle of Operation

15. DC Generator

17. 00 Position (DC Neutral Plane)
900 Position (DC)
1800 Position (DC)
2700
Position
(DC)
00 Position (DC
Neutral Plane)

18. DC Motor

19. Schematic diagram of DC Motor

20. DC motors

21. DC Motor
(Physical Cut Section)
Cutaway view of a dc motor Stator with poles visible.

22. segments
brushes
Rotor of a dc motor.

30. AC Generator

31. AC motor Classification

32. Induction Motor

33. Squirrel cage Induction Motor

34. Synchronous Motor

35. Stepper motor
• The motor converts electrical pulse into
discrete mechanical movements.
• 2°, 2.5°, 5°, 7.5°, 15° rotations per input
electrical pulse.
• Speed of motor shaft ∝ Frequency of input
pulses.

36. Stepper Motor

37. Basic parts of any Motor

38. Properties of stepper motor
• Open – Loop control system
• Rotates in both direction
• Self locking when rotor is stationary
• Excellent positional accuracy

39. Types of Stepper motor
1. Permanent magnet stepper motor
2. Variable reluctance stepper motor
3. Hybrid stepper motor

40. Permanent Magnet Stepper motor
• No teeth

42. Construction of Permanent magnet
Stepper motor
No teeth in permanent magnet stepper motor

43. No. of Poles ∝ Steps

45. Working of Permanent Magnet
Stepper motor

49. Construction of Variable Reluctance
Stepper motor
• Multi tooth – Soft
iron core.
• No. of poles on rotor
< No. of poles on
stator
• Stator coil windings –
DC current – poles
get magnetized.

50. Construction of Variable Reluctance
Stepper motor

51. Construction of Variable Reluctance
Stepper motor

56. Half Step in VR stepper motor

58. Variable reluctance Stepper motor

59. Hybrid Stepper motor
• Combination of VR & PM SM
• Rotor & stator are multi toothed.

60. Hybrid Stepper motor

62. Construction of Hybrid Stepper Motor

63. Construction of Hybrid Stepper Motor

64. Construction of Hybrid Stepper Motor

65. Construction of Hybrid Stepper Motor
Half Aligned
Half Aligned
Unaligned
Fully Aligned

66. Construction of Hybrid Stepper Motor

67. Working of Hybrid Stepper Motor

68. Working of Hybrid Stepper Motor

69. Working of Hybrid Stepper Motor

71. Step modes of Stepper motor
• Full step mode – 1.8 step
• Half step mode – 0.9 step
• Microstep mode – 1/256 steps or 50,000 steps
per revolution

74. Servo motor
• Rotation for certain angle for long period of
time.
• Special type of motor which is automatically
operated up to certain limit for a given
command with help of error-sensing feedback
to correct the performance.

78. Types of Servo motor
1. DC Servo motor
2. AC servo motor

79. DC Servo motor

80. Construction of Servo Motor

81. Working principle

83. Working principle

84. AC servo motor

85. Construction of AC Servo motor

86. Construction of AC Servo motor

87. Working Principle

88. Working Principle

89. Advantages & Disadvantages of
Servo motor
• Closed loop
• High efficiency up to 90% at light loads
• High output relative to motor size and weight
• AC servo motor is low cost
• No linear characteristics
• Complex design, Needs encoder
• DC servo motor is costly but widely used
• Brushes wears out to 2000hrs
• Services and maintenance required.

92. Comparison of Stepping motor and
Servo motor

93. First half of this unit ends here

94. Stages in designing mechatronics
system

95. Mechatronics design approach

100. 3 Design Stages
1. Conceptual design
2. Embodiment design
3. Production Design Cycle

101. • Initiating design – potential solution –
best concept
• Highly creative process & requires
coordination
• Consists of:
– Customer need identification
– Problem definition (Goal)
– Gathering Information (Literature Survey)
– Concept generation
– Concept selection
Stage 1: Conceptual design

102. Stage 1: Conceptual design

103. • Preliminary design – ‘skeleton’
• After this stage, only minor design
modification
• Consists of:
– product architecture – subsystem and
its relation
– configuration design of part and components
– mathematical modeling and simulation
– sensors and actuators selection
– controller design
Stage 2: Embodiment design

104. • Prototyping
– approximation of a product
– Proof of concept
– E.g sketch, model, 3D drawing or fully
functional product
• Stage 3: Production
Stage 2: Embodiment design

108. • What World Think Of Indians?

111. Traditional vs Mechatronics Approach

113. Traditional vs Mechatronics Approach

114. Traditional vs Mechatronics Approach
Examples
1. Windscreen Wiper (Motor vs Stepper Motor)
2. Weighing gauge (Mechanical vs Strain
gauges)
3. Timer Switch (Cam vs PLC operated)

115. Traditional vs Mechatronics Approach
Examples
1.Windscreen Wiper
(Motor vs Stepper
Motor)
2. Weighing gauge (Mechanical vs Strain
gauges)
3. Timer Switch (Cam vs PLC operated)

116. Windscreen wiper

119. Traditional vs Mechatronics Approach
Examples
1. Windscreen Wiper (Motor vs Stepper Motor)
2.Weighing gauge
(Mechanical vs Strain
gauges)
3. Timer Switch (Cam vs PLC operated)

120. Weighing scale Traditional approach

121. Weighing scale Traditional approach

122. Weighing scale Mechatronic approach

124. Block diagram of Electronic Weighing
machine
Whetstone
bridge
(Load cell or
strain gauge
connected)
Amplifier ADC
Display
device
(LED, LCD)
Display driver
Power supply

126. Case Studies
1. Pick and Place Robot
2. Engine Management System
3.Automatic Car park barrier

127. Case Studies
1. Pick and Place
Robot
2. Engine Management System
3.Automatic Car park barrier

128. Pick and Place robot

130. -

133. Before understanding the working of
Pick and place Robot
• Microprocessor, Microcontroller
• DCV – Direction Control Valve in Hydraulics
and Pneumatics
• TRIAC

134. Before understanding the working of
Pick and place Robot
•Microprocessor,
Microcontroller
• DCV – Direction Control Valve in Hydraulics
and Pneumatics
• TRIAC

137. Before understanding the working of
Pick and place Robot
• Microprocessor, Microcontroller
•DCV – Direction Control
Valve in Hydraulics and
Pneumatics
• TRIAC

141. Understanding Way (Ports)
and Position (Directions)

142. Simple Push button actuation

144. 4/2 way DCV

145. Name the DCV?

146. 5/2 Way DCV

147. 5/3 way DCV

149. Before understanding the working of
Pick and place Robot
• Microprocessor, Microcontroller
• DCV – Direction Control Valve in Hydraulics
and Pneumatics
•TRIAC

150. TRIAC
• Triac used as a simple static AC
power switch providing an “ON”-
“OFF” function similar in
operation to the previous DC
circuit.

151. Diode

154. Covalent Bond

155. Doping

156. Doping

158. Barrier potential

161. Diode

162. Diode

164. Transistor

177. Silicon Controlled Rectifier (SCR)

180. Physical Construction of TRIAC

183. Opto-Triac
• Photodiode or Photo Transistor

184. Pick and Place Robot
• Movements in Pick and Place
Robot:
– Clockwise & anticlockwise of
robot unit on its base
– Linear movement (extension or
contraction)
– Up & down movement of arm
– Open & close movement of
gripper

185. Pick and Place Robot
• Robot consists of:
1. Rover – main body
2. End effectors or Grippers
3. Sensors
4. Actuators
5. Controller

186. Microcontroller
Display
(LCD)
Teach pendent
(PLC)/ Keypad
Electro-
Pneumatics
Base actuator
(Clockwise &
anticlockwise)
Basic Block diagram for Pneumatically actuated Pick and Place Robot
Electro-
Pneumatics
Electro-
Pneumatics
Electro-
Pneumatics
Up & Down
movement of Arm
Extension &
Retention of Arm
Open & Close of
End
Effector/Gripper

189. Advancement in Pick & Place Robot

190. Applications of Pick & Place Robot
• Defence applications
• Industrial application
• Medical application

192. Case Studies
1. Pick and Place Robot
2. Engine
Management
System
3.Automatic Car park barrier

194. EMS

197. EMS
• ECU
• Throttle position sensor
– Throttle opening and force applied by the driver
– Controls fuel delivery & spark ignition
– Potentiometer and Hall effect sensor
• EGO – Exhaust gas Oxygen sensor
– Amt of Oxygen in exhaust system
– Lambda (l) Sensor
– ZrO2/ Pt electrodes

198. EMS
• MAP
– Vacuum in manifold
– Piezoelectric & capacitive sensor
• Temp sensor
– Cabin, Engine, etc
– Activates cooling fan
– Thermistor, Thermodiode, thermocouple

199. EMS
• EGR
– Low HC level in exhaust
• MAF sensor
– Engine load to spray right amt of fuel
– Hot wire airflow sensor (Anemometer)
• Knock sensor
– Unburnt fuel inside will before ignition starts
– Piezoelectric sensor

203. Case Studies
1. Pick and Place Robot
2. Engine Management System
3.Automatic Car
park barrier

204. Before understanding a Car Park
barrier
• Basic knowledge of PLC ladder diagram

205. Relay Operation

206. Ladder diagram used to write PLC
program

207. Ladder Logic

208. Ladder diagram

209. Traditional vs Mechatronics Approach
Examples (Contd..)
1. Windscreen Wiper (Motor vs Stepper Motor)
2. Weighing gauge (Mechanical vs Strain gauges)
3.Timer Switch
(Cam vs PLC
operated)

211. Mechatronics Approach

212. Automatic car park barrier

215. Automatic Car park barrier
(Coin operated)

216. Automatic Car park barrier
(Coin operated)

217. Automatic Car park barrier
(PLC - Coin operated)

218. Ladder diagram for Automatic Car
park barrier

219. Unit 5 ends here
Basic ideas about Part-C questions

220. Autonomous Mobile Robot (AGV)

221. Autonomous Mobile Robot (AGV)

223. Driverless Trains

224. Pallet Trucks

225. Unit Load Carrier

226. Automated Guided Vehicle

229. Locomotion
• Legged
• Snake
• Free-floating
• Wheeled
• Swimming
• Flying
• Swarm

230. Sensory perception & Knowledge
representation
• Knowledge representation
– Ability to model the world
– Recognize certain object in an environment
• AGV – communicate to humans about the
location of victims and hazards
• IoT – use Maps

232. Planning, Autonomy and
Collaboration

233. Factors
• Dimensions, mass of objects to be handled
• Actuators
• Power source
• Range of gripping force
• Positioning
• Environment
• Protection from hazards

234. Application of AGV
• Nuclear Accident cleanup
• Planetary exploration
• Mail delivery

235. Wireless Surveillance Balloon

237. Wireless Surveillance Balloon
• Image sensors
• Thermal sensors
• Audio sensors
• Location sensors
• Altitude sensors
• A compass and
• Motion sensors
• Aerostats – LTA (Lighter than Air- He, H) balloons.

238. Applications
• Border security
• Coastal surveillance
• Platform for telecommunication, TV, radio
transmission
• Aerial platform for Scientific instrument
testing
• Aerial platform for Weather prediction
• Terrestrial mapping

240. Elevator system

241. s

243. Mechatronic System Examples
(Maybe asked as Part C in Univ exam)
• Robots
• Printer System (3D)
• Photocopying machines
• Bar code reader
• Any Home appliances (TV,
CD player, remote, Fridge,
Air conditioner, Sewing
machines etc.,)
• Automatic door systems
• Automatic security system
• ABS
• Fuel injection systems
• Sorting and packaging
systems (Packing
machines)
• CNC
• Heat-seeking missiles
• CMM
• ATM
• Medical field (magnetic
resonance, ultrasonic
probes, arthroscopic
devices)
• Digital thermostat