INTRODUCTION

ELEMENTS OF MECHATRONICS

By

V. THULASIKANTH
Assistant Professor
Mechanical Engineering Department
vtkvsk@gmail.com

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 Topics
SL.NO TOPIC

1 Introduction to Mechatronics systems,

Concepts & Application.

2 Mechatronics System Components with

examples
3 Measurement Systems, Control systems,
Open & Closed Loop Systems.
4 Sequential Controllers with examples –
Water level controller.
5 Shaft speed control, Washing machine
control.
6 Automatic camera and Engine
2 management systems.
Introduction to Mechatronics Systems
The word mechatronics was originated from Japan (Yasakawa Electric Company) in the
late 1960s, spread through Europe, and is now commonly used round the globe.

“The word, mechatronics, is composed of ‘mecha’ from mechanism and the ‘tronics’
from electronics.

Mechatronics solves technological problems using interdisciplinary knowledge consisting

of mechanical engineering, electronics, and computer technology.

In 1996, Harashima, Tomizuka, and Fukuda defined mechatronics as being “the
synergistic integration of mechanical engineering, with electronics and intelligent computer
control in the design and manufacturing of industrial products and processes.”

Bolton presented yet another definition by saying “a mechatronic system is not just a
marriage of electrical and mechanical systems and is more than just a control system; the
mechatronic system is a complete integration of them all.”

Mechatronics is the field of study concerned with the design, selection, analysis, and
control of systems that combine mechanical elements with electronic components,
including computers and/or microcontrollers.
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 Working definition
Mechatronics is the synergistic integration of sensors, actuators, signal conditioning, power
electronics, decision and control algorithms, and computer hardware and software to
manage complexity, uncertainty, and communication in engineered systems.

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Graphical Representation of Mechatronics
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 Evolution of Mechatronics
Technological advances in design, manufacturing, and operation of engineered
products/devices/processes can be traced through:

– Industrial revolution
– Semiconductor revolution
– Information revolution
Industrial Revolution

• Allowed design of products and processes for energy conversion and transmission thus
allowing the use of energy to do useful work.

• Engineering designs of this era were largely mechanical

– e.g., operations of motion transmission, sensing, actuation, and computation were
performed using mechanical components such as cams, gears, levers, and linkages).

• Purely mechanical systems suffer from

– Power amplification inability.
– Energy losses due to tolerances, inertia, and friction.

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 Semiconductor Revolution

• Led to the creation of integrated circuit (IC) technology.

• Effective, miniaturized, power electronics could amplify and deliver needed amount of
power to actuators.

• Signal conditioning electronics could filter and encode sensory data in analog/digital
format.

• Hard-wired, on-board, discrete analog/digital ICs provided rudimentary computational

and decision-making circuits for control of mechanical devices.

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 Information Revolution
• Development of VLSI technology led to the introduction of microprocessor,
microcomputer, and microcontroller.

• Now computing hardware is everywhere, cheap, and small.

• As computing hardware can be effortlessly interfaced with real world electromechanical

systems, it is now routinely embedded in engineered products/processes for decision-
making.
– Microcontrollers are replacing precision mechanical components, e.g., precision
machined camshaft that in many applications functions as a timing device.

– Programmability of microcontrollers is providing a versatile and flexible alternative to the

hard-wired analog/digital computational hardware.

– Integrated computer-electrical-mechanical devices are now capable of converting,

transmitting, and processing both the physical energy and the virtual energy (information).

• Result: Highly efficient products and processes are now being developed by
judicious selection and integration of sensors, actuators, signal conditioning, power
electronics, decision and control algorithms, and computer hardware and software.

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 Mechatronics has evolved through the following stages:
• Primary Level Mechatronics: Integrates electrical signaling with mechanical action at the
basic control level for e.g.fluid valves and relay switches

• Secondary Level Mechatronics: Integrates microelectronics into electrically controlled

devices for e.g. cassette tape player.

• Tertiary Level Mechantronics: Incorporates advanced control strategy using

microelectronics, microprocessors and other application specific integrated circuits for e.g.
microprocessor based electrical motor used for actuation purpose in robots.

• Quaternary Level Mechatronics: This level attempts to improve smartness a step ahead
by introducing intelligence ( artificial neutral network and fuzzy logic ) and fault detection
and isolation ( F.D.I.) capability into the system.

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 Mechatronics Applications
• Smart consumer products: home security, camera, microwave oven, toaster, dish washer,
laundry washer-dryer, climate control units, Automatic Digital Cemera etc.

•Computer disk VCR/DVD drives, ATM, etc

• Medical: implant-devices, assisted surgery, haptic, etc.

• Defense: unmanned air, ground, and underwater vehicles, smart weapons, jet engines, etc.

• Manufacturing: NC & CNC machine tools, Rapid Prototyping, robotics, etc.

• Automotive: climate control, antilock brake, active suspension, cruise control, air bags,
engine management, safety, etc.

• Network-centric, distributed systems: distributed robotics, telerobotics, intelligent highways,

etc.

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 Advantages of Mechatronics
Cost effective and good quality products
High degree of flexibility to modify or redesign
Very good performance characteristics
Wide are of application
Greater productivity in case of manufacturing organization
Greater extend of machine utilization

Disadvantages of Mechatronics
High Initial cost
Multi-disciplinary engineering background required to design and implementation
Need of highly trained workers
Complexity in identification an correction of problems in the system

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 Elements of Mechatronics System
Actuators & Sensors

Signals & Conditioning

Digital Logic System

Software & Data

acquisition Systems

Computers & Display

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devices
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 Actuators & Sensors
Sensors and actuators come under mechanical systems

Actuators Sensors

The actuators produce The sensors detect the state

motion or cause some action of the system parameters,
inputs and outputs

Various actuators: Pneumatic Various Sensors: Liner and

an hydraulic actuators, rotaional sensors,
Electro Mechanical actuators, acceleration sensors, force,
Piezoelectric, Electrical torque, pressure sensor,
Motors, i.e. D.C, A.C, Stepper, temperature, proximity and
Servo motors. light sensors.

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 Signals & Conditioning
Mechatronic system deals with two types of signals and conditioning , i.e.
Input & Output
Input devices receive input signals from the mechatronics system via
interfacing devices an sensors.
From sensors the signal is send to the control circuits for conditioning or
processing.
Various input signal conditioning devices are amplifiers, A2D, D2D converters .
Output signals from the system are send to the output/display devices through
interfacing devices
Various output signal conditioning devices are D2A, display decoders, power
transistors, op-amps.

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 Digital Thermometer

The thermocouple is a transducer that converts temperature to a small voltage; the

amplifier increases the magnitude of the voltage; the A/D (analog-to-digital)
converter is a device that changes the analog signal to a coded digital signal; and the
LEDs (light emitting diodes) display the value of the temperature.

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 Digital Logic System
It will control overall system operation

Various digital logic systems are logic circuits, microcontrollers, PLC, sequencing &
timing controls

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 Software & Data acquisition Systems
Data acquisition system acquires the output signals from sensors in the form of
voltage, frequency, resistance etc. an inputting into the microprocessor or
computer.

Software is used to control the acquisition of data through DAC board.

Data acquisition system consists of multiplexer, amplifier, register and control

circuits.

Software Examples: Ladder Logic, Visual C++, Visual Basic, Lab VIEW, MATLAB,
Lab Chart, LOX

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 Using Lab VIEW

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 Computers and display devices
Computers are use to store large amount of data and process further through
software.

Display devices are used to give visual feedback to the user.

Display devices are LED, CRT, LCD, Digital displays etc.

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 Measurement System

What is a system?

Input, Output,
Electrical Power Rotaion
MOTOR

Not concentrate on what goes on inside

Concentrate only on output & Input device

Measurement system?
Output
Measuring Input quantity Measurement the value of
System quantity

Output
Input Temp. Thermometer number on
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scale
 Digital Thermometer

The thermocouple is a transducer that converts temperature to a small voltage; the

amplifier increases the magnitude of the voltage; the A/D (analog-to-digital)
converter is a device that changes the analog signal to a coded digital signal; and the
LEDs (light emitting diodes) display the value of the temperature.

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 Control System
To control the output to some particular value or particular sequence of values

Input, required Central Heating Output, temperature at the set

temperature system value

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Difference between Open loop and Closed loop system

SI.No. Open loop system Closed loop system

1 Not using feedback Feedback using

2 Less accurate More accurate

3 Simple in construction Complicated in construction

4 Optimisation in control is not possible Optimisation in control is possible

5 Easy maintenance & cost is less Difficult to maintain & cost is more

6 Eg. CD deck, Digital thermometer Eg. Automatic water level, washing

machine
Open Loop system
Closed loop system
Basic Elements of a closed loop system

1. Comparison element
2. Control element
3. Correction element
4. Process elements
5. Measurement elements
 Various elements for controlling the room
temperature.

Controlled variable - the room temperature

Reference value - the required room temperature
Comparison element - the person comparing the measured value wit required temp.
Error signal - difference between measured and required temperatures
Control unit - the person
Correction unit - the switch on the fire
Process unit - the heating by the fire
Measuring device - a thermometer
Shaft Speed Control
Water Level Controller
Washing machine control
Cam operated Switch
Engine Management system
Automatic Camera
The Digital Camera