TECHNOGADGET SESSION 1

1. Definition

The term Mechatronics was first created in Japan in the 1960s. Numerous definitions of Mechatronics
can be found on the internet, journals, and on several books. Mechatronics is the synergistic
integration of mechanical engineering with electronics and electrical systems with intelligent
computer control in the design and manufacture of industrial products, processes, and operations
(Hegde, 2010). Meanwhile, Alciatore and Histand (2007) referred to it as a rapidly evolving,
interdisciplinary field of engineering dealing with the design of products whose function relies on the
integration of mechanical and electronic components coordinated by control architecture.

The Institute of electrical and electronics engineers and American society of mechanical engineers
(IEEE/ASME) transactions on Mechatronics, defines it as the synergetic integration of mechanical
engineering with electronic and intelligent control in the design and manufacture of industrial
products and processes. Auslander (1996) in his paper defined it as the application of complex
decision making to the operation of physical systems. However, Wikipedia defines mechatronics as a
design process that includes a combination of mechanical, electrical, telecommunication, control,
and computer engineering. With complex definitions of the word mechatronics, no one would argue
that mechatronics over the years has improved the quality of life. Applications of this subject range
from simple consumer products, appliances, vehicle applications, power management systems,
manufacturing technologies and automation. This book will give basic appreciation in this field. The
student would be able to learn the basic mechatronic system and its sub-systems through
combination of theories and hands-on exercises. The different subsystems will be discussed in detail in
the succeeding sessions. At the end of this course, the student would be able to design and
implement a simple mechatronic system.

2. Objectives

Mechatronics is very diverse and flexible. It can be used to a wide array of applications;hence a lot of
objectives can be derived from this. Hegde (2010) summarized a list of objectives.

Design objective – minimize size and number of components

Data extraction objective – use of proper sensors
Output generation – translation and rotation thru the use of motors
Processing objective – processing of data with the aid of microprocessors
Control objective – feedback control system
Communication objective – proper communication networks
Automation objective – system integration, data integration
Display objective – monitors and LED digital displays
Performance objective – refinement and accuracy of outputs

3. Systems

Mechatronic systems even with different objectives are very basic and the same. The basic system as
shown in Figure 1 has three main parts: inputs, system and outputs. Fundamentally, a mechatronic
system will acquire physical data from its inputs through the use of sensors, switches or user commands.
Then, it will send the data to the system where there will be a set of instructions programmed by the
user. Based on the set of instructions, the system will provide signals to the outputs for corresponding
action like motion or indication. Therefore, the system is a combination of mechanical, electrical, or
electronic requiring compatible inputs.

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Inputs System Outputs

(Sensors or
Command) (Microcontroller or PLC) (Actuators or
Display)

Physical Parameters Motion

User Input Indication

Figure 1: Mechatronic System

4. Industrial/Commercial applications

Mechatronic applications are widespread and can be found in all aspects of life. Typical home
appliances like a computer controlled air-conditioner and automatic washing machine operate using
the principles of mechatronics. In modern vehicles, anti-lock braking system (ABS) and various engine
management systems such as VTEC, VVT and others. are also mechatronic applications. Modern
manufacturing systems use mechatronics to automate certain manufacturing processes such as
quality control and assembly procedures. The succeeding paragraphs will discuss in detail some
mechatronic applications found in a normal household.

Automatic Washing Machine

Nowadays, most of us use an automatic washing machine to do our laundry. The washing operation
in a washing machine that is used to wash clothes has a set of sequences which include: 1. Pre-wash
cycle; 2. Main wash cycle; 3. Rinse cycle; 4. Spin cycle and 5. Dry cycle (optional). To automatically
carry out these cycles, the machine is equipped with a microprocessor-based controller, sensors,
drivers and heater. Based on the inputs from the user and the sensors, the washing machine will be
able to detect the corresponding program and wash cycle. The duration, amount of water and load
are also automatically detected by the sensors which will enable the washing machine to select the
appropriate mode (light, medium, heavy). Figure 2 shows a typical washing machine.

Inputs System Outputs

Manual Program Motor

Temperature sensor Pump

Load sensor Heater

Washing Machine
Water level sensor Valve

Speed sensor

Figure 2: Automatic washing machine system

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Automatic Soap Dispensers

Automatic soap dispensers can be seen in a lot of mall restrooms as they prove to be very hygienic.
Nowadays, consumers can also buy portable automatic soap dispensers for household use. This
device is very simple to use. Put your hand under the dispenser and a certain amount of liquid soap
will be dispensed on your hand. So how does it function? A proximity sensor senses the presence of a
hand at a certain distance then it sends a signal to the controller. The controller based on the signal
will command the motor to function causing the pump to activate and dispense liquid soap on your
hand. The portable soap dispenser is shown in Figure 3.

Inputs System Outputs

Proximity sensor Pump Motor

Portable soap
dispenser
Hand motion Liquid soap dispenses

Figure 3: Portable soap dispenser

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PLC example – Stamping Machine

Stamping is a common process in manufacturing. The design of the stamping sequence is usually
based on the components used such as input components, Programmable Logic Controller (PLC)
programmer and output components.

In this example of a stamping machine, a toggle and limit switch must be both switched to energize a
solenoid that will extend a pneumatic stamping cylinder. An embedded timer will indicate how long
must the stamping solenoid be energized. Once the set time is over, the second limit switch is
activated. This second limit switch indicates the end of a stroke. At this point, the solenoid should be
de-energized; thus, retracting the cylinder.

Inputs System (PLC) Outputs

Toggle switch Energized

Pneumatic
cylinder solenoid

Timer Solenoid will remain Second limit

switch energized

De-energized
Second limit Solenoid Retracting
Switch the cylinder

Figure 4: Stamping machine schematic

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Assignment # 1: Apprehending Mechatronic Systems

Learn different approaches and other applications of Mechatronics in your everyday life.

1. Define Mechatronics based on your own understanding.

2. Research on some advantages and disadvantages of Mechatronics.

3. Enumerate other industrial applications in Mechatronics. Briefly explain how such applications
made life better.

4. Research on other applications that use PLC.

5. Look around your house and find other Mechatronics applications not mentioned in this book.
Draw a basic block diagram (inputs, system, outputs) of that application.

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