MECHANICAL ENGINEERING

For
UPSC Engineering Services Examination, GATE,

State Engineering Service Examination & Public Sector Examination.

(BHEL, NTPC, NHPC, DRDO, SAIL, HAL, BSNL, BPCL, NPCL, etc.)

HGH

MECHATRONICS
AND ROBOTICS

Office : F-126, (Lower Basement), Katwaria Sarai, New Delhi-110016 Phone : 011-26522064
Mobile : 8130909220, 9711853908 E-mail: info@iesmasterpublications.com, info@iesmaster.org
Web : iesmasterpublications.com, iesmaster.org
IES MASTER PUBLICATION
F-126, (Lower Basement), Katwaria Sarai, New Delhi-110016
Phone : 011-26522064, Mobile : 8130909220, 9711853908
E-mail : info@iesmaster.org, info@iesmasterpublications.com
Web : iesmasterpublication.org, iesmaster.org

All rights reserved.

Copyright © 2017, by IES MASTER Publications. No part of this booklet may be reproduced,
or distributed in any form or by any means, electronic, mechanical, photocopying, recording,
or otherwise or stored in a database or retrieval system without the prior permission of IES
MASTER, New Delhi. Violates are liable to be legally prosecuted.

First Edition : 2017

Typeset at : IES Master Publication, New Delhi-110016

 CONTENTS
MECHATRONICS
1. Sensors and Actuators............................................................................... 1–26

2. Control Systems ....................................................................................... 27–56

3. Microprocessor & Micro controllers ..................................................... 57–126

ROBOTICS
4. Robotics ................................................................................................. 127–200
 1
INTRODUCTION

Sensors and Actuators  Mechatronics is the synergetic use of precision engineering, control
theory, computer science, and sensor and actuator technology to
design improved products and processes.
 It is the methodology used f or the optimal design of
electromechanical processes.
 The name was coined by Ko Kikuchi, the president of Yasakawa
Electric company, Chiyoda-Ku, Tokyo.
 The domain of mechatronics includes the synergetic integration of
sensors, actuators, signal conditioning, power electronics, decision
and control algorithms, and computer hardware and software to
manage complexity, uncertainity, and communication in engineered
systems.

Micro-
computers Actuators Process

Sensors

SENSORS AND ACTUATORS

 Two critical components of a mechatronics system are sensors
and actuators.
 A typical mechatronics system consists of a sensing unit, a
controller and an actuating unit
 A sensing unit consists of a sensor and a combination of additional
components such as filters, amplifiers, modulators and other signal
conditioners.
2 / MECHATRONICS AND ROBOTICS

 The controller, after accepting information from the sensing unit, makes decision based on the
control algorithm and sends output commands to the actuating unit.
Sensors and actuators are now dealt in detail below:
Sensors
 Sensor is a device that produces a proportional output signal when exposed to a physical phenomenon.
Ideally,a sensor is a device that responds to a change in the physical phenomenon.
 Sensors are tranducrers when they sense one form of energy as input and produce output in a
different form of energy.
Classification of sensors
1. Linear and Rotational Sensors
 These are two of the most fundamental sensors for all the measurements used in a typical
mechatronics system.
 These sensors produce an electrical output that is proportional to the displacement they experience.
 These are of two types:
(i) Contact type - LVDt, RVDT, tachometer etc.
(ii) Non-contact type - encoders, hall-effect transducers, interferometer type
 High Resolution type of sensors such as hall-effect, optic inductance, capacitance and strainn gauge
are suitable for only small range.
 Differential transformers on the other hand, have a much larger range with good resolution.
 Interferometer type sensors are bulky, expensive and requires large set up time.
 Strain gauge provides high resolution at low noise level and is least expensive.

 Few important examples are discussed below:

(i) Hall Effect Transducer :

 The principle of working of a Hall effect Transducer is that: If a strip of conducting material carries
a current in the presence of a transverse magnetic field, a difference of potential is produced
between the opposite edges of the conductor. The magnitude of the voltage depends upon the
current, the strength of magnetic field and the property of the conductor. This is called Hall effect.
l
Half VH
strip 2

w 3 4 I
e– e– e–
t
A
Transverse
magnetic field (B)
Two forces acts on the electron constituting current one is due to magnetic field (B) and one due
to electric field EH  i.e. hall field developed across width w..

Thus at steady state,

Regd. office : F-126, (Lower Basement), Katwaria Sarai, New Delhi-110016 Phone : 011-26522064
Mob. : 8010009955, 9711853908 E-mail: ies_master@yahoo.co.in, info@iesmaster.org
Web : iesmasterpublications.com, iesmaster.org
 SENSORS AND ACTUATORS / 3

E He  = v d Be 

e = charge of electron
vd = drift velocity of electron
 EH = vdB ...(1)
and VH = Hall potential = EH  w ...(2)
Therefore using (2) in (1), we get

VH = v dBw ...(3)

We know that I = nv d wte ...(4)

Substituting w from (4) in (3), we get

v dBI
VH = nv  t  e
d

 1   BI 
VH =       ...(4)
 ne   t 
1 1
KH = Hall coefficient = 

ne 
where
n = number density of electrons in conductor (columb/m 3)
 = charge density

Measurement of Displacement by Hall Effect Transducer :

Air gap
Moving Plate

Hall effect
element
Displacement
A
VH

Fig. Hall Pick up

As displacement x is proportional to air gap which increases reluctance of magnetic flux path and
thus changes Magnetic flux density, which by equation (4) changes hall voltage which can be measured
indicating displacement.
x  B  VH
Displacement is measured in m range.

Regd. office : F-126, (Lower Basement), Katwaria Sarai, New Delhi-110016 Phone : 011-26522064
Mob. : 8010009955, 9711853908 E-mail: ies_master@yahoo.co.in, info@iesmaster.org
Web : iesmasterpublications.com, iesmaster.org
4 / MECHATRONICS AND ROBOTICS

Appliction of Hall effect Transducer:

1. Magnetic to electric Transducer
2. Measurement of displacement
3. Measurement of current
4. Measurement of power
(ii) Resolvers :
– The function of a resolver is to resolve a vector into its sine and consine components.
– The output of the resolver is in the form of two signals, one proportional to the sine of the
angle and the other proportional to cosine of the angle.
– Hence, resolvers are used for the conversion of angular position of a shaft into cartesion
coordinates.
– A resolver is an analog electromagnetic transducer that can be used in a wide variety of
position and velocity feedback applications ranging from semiconductor manufacturing to oil
and gas drilling.
– Resolver is an analog device and the electrical outputs are continuous through one complete
mechanical revolution and hence, it offers infinite theoretical resolution.
– Basic principle of working:
(i) The device consists of a rotor attached to a shaft that moves with the load, and a stator
that remains stationary.
(ii) Stator windings are supplied with an alternating voltage that produces an alteranting
magnetic flux which induces voltages in the two rotor windings.
(iii) The output voltage of the rotor windings is proportional to the stator voltage and the
coupling between stator and rotor windings.
(iv) The way in which the windings are placed, the rotor output voltages are proportional to
the sine and cosine of the rotor angel.
S2 ES2–4 S4

Stator windings
R1

S1
ES ER
1–3 1–3

S3 Rotor
windings
ER R3
2–4

R2 R4
(iv) When one of the stator windings S1S3 is excited by an a.c. source then S2S4 gets short
circuited. The output voltage is given by

Regd. office : F-126, (Lower Basement), Katwaria Sarai, New Delhi-110016 Phone : 011-26522064
Mob. : 8010009955, 9711853908 E-mail: ies_master@yahoo.co.in, info@iesmaster.org
Web : iesmasterpublications.com, iesmaster.org
 SENSORS AND ACTUATORS / 5

ER13  ES13 cos 

ER24  ES13 sin 

(v) When the two stator windings are excited, the output is given by
ER13  ES13 cos   ES2 4 sin 

ER24  ES2 4 cos   ES13 sin 

(vi) When the two rotor windings are excited, we get the following outputs from the stator
windings.
ES13  ER13 cos ER2 4 sin 
ES2 4  ER2 4 cos ER13 sin 
(iii) Inductosyn :
– An inductosyn is a type of inductive position sensing device.
– An industosyn transducer consists of two non-contacting elements, a scale and slider for the
linear transducer and a rotor and stator for rotary transducer.
V2 = +E
Winding W2
+ – Xp

Winding W1

+ v1 –

– Inductosyn position transducers are ‘printed circuit’ form of an electrical resolver and can be
printed on almost any substrate material.
– The most common inductosyn transducer application uses inductive coupling between the
moving parts.
– The induced voltage, V2 is at the maximum amplitude when the winding conductors W 2 of one
element one exactly aligned with the winding conductors W 1 of the other element.
– The induced voltage, V2 passes through zero when the winding conductors W 2, if one element
are midway between the winding conductors, W 1 or the other element.
2. Acceleration sensors
 Measurement of acceleration is important for systems subjected to shock and vibration.
 Two most common type of accelerometers are seismic mass type accelerometers and the piezoelectric
accelerometers.
 The seismic mass type accelerometer is based on the relative motion between a mass and the
supporting structure. But the natural frequency of the seismic type limits its use to low to medium
frequency applications.
 The piezoelectric accelerometer are compact and more suitable for high frequency application.

Regd. office : F-126, (Lower Basement), Katwaria Sarai, New Delhi-110016 Phone : 011-26522064
Mob. : 8010009955, 9711853908 E-mail: ies_master@yahoo.co.in, info@iesmaster.org
Web : iesmasterpublications.com, iesmaster.org