Mechatronics Lab Manual

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DEPARTMENT OF MECHANICAL ENGINEERING
LAB MANUAL
2013 Regulations
Subject Code : ME 6712
Subject Name : MECHATRONICS
Year/Semester : IV/VII
Authors
1. Prof.S.Arun. BE (Mech)., ME(CAD)
Assistant Professor
Department of Mechanical Engineering
Vel Tech (Owned By RS Trust)
Avadi, Chennai-62
2. Prof.N.K.Karthickeyan. BE (Mech)., ME (CAD)
Assistant Professor
Department of Mechanical Engineering
Vel Tech (Owned By RS Trust)
ME6712
Avadi, Chennai-62
www.Vidyarthiplus.com
SYLLABUS
ME6712 MECHATRONICS LABORATORY LTPC

0 03 2
OBJECTIVES:
 To know the method of programming the microprocessor and also the design, modeling &analysis of
basic electrical, hydraulic & pneumatic Systems which enable the students to understand the concept of
Mechatronics.
LIST OF EXPERIMENTS:
1. Assembly language programming of 8085 – Addition – Subtraction – Multiplication – Division

– Sorting – Code Conversion.
2. Stepper motor interface.
3. Traffic light interface.
4. Speed control of DC motor.
5. Study of various types of transducers.
6. Study of hydraulic, pneumatic and electro-pneumatic circuits.
7. Modeling and analysis of basic hydraulic, pneumatic and electrical circuits using Software.
8. Study of PLC and its applications.
9. Study of image processing technique.
OUTCOMES:
• Upon completion of this course, the students can able to design Mechatronics system with the
help of Microprocessor, PLC and other electrical and Electronics Circuits.
LIST OF EQUIPMENT FOR A BATCH OF 30 STUDENTS
Sl. No. NAME OF THE EQUIPMENT Qty.

1 Basic Pneumatic Trainer Kit with manual and electrical 1 No
controls/ PLC Control each
2 Basic Hydraulic Trainer Kit 1 No
3 Hydraulics and Pneumatics Systems Simulation Software 10 Nos
4 8051 - Microcontroller kit with stepper motor and drive 2 Nos
circuit sets
5 Image processing system with hardware & software 1 No
1. INTRODUCTION TO MECHATRONICS SYSTEM
MECHATRONICS SYSTEM:
Mechatronics is one of the new and existing fields on the engineering landscape, subsuming parts of
traditional engineering fields and requiring a broader approach to the design of system that we can formally call
as Mechatronics system.
Many industries improving their works through automation which is based on the inter connection
between the electronic control systems and mechanical engineering.
Such control systems generally use microprocessors as controllers and have electrical sensors extracting
information from mechanical inputs through electrical actuators to mechanical systems.
This can be considered to be application of computer based digital control techniques through electronic
and electric interfaces to mechanical engineering problems. Successful design of Mechatronics can lead to
products that are extremely attractive to customer in quality cost-effectiveness.
“Mechatronics brings together areas of technology involving sensors and measurement systems, drive
and actuation systems, analysis of the behavior of systems microprocessor systems”.
The integration across the traditional boundaries of mechanical engineering, electrical engineering,
electronics and control engineering has to occur at the earliest stages of the design process if cheaper, more
reliable; more flexible systems are to be developed.
APPLICATIONS OF MECHATRONICS ENGINEERING:
Mechatronics engineering finds application in the following fields.
 Electronic home appliances

 Electronic entertainment products
 Engine systems (cars)
 Large scale application
2. ASSEMBLY LANGUAGE PROGRAMMING OF 8085 ADDITION OF TWO 8-BIT NUMBERS
AIM:
To write an assembly language program to add two 8-bit numbers.
APPARATUS REQUIRED:
 8085 Microprocessor kit

 Power supply cable
ALGORITHM:
Step 1: Initialize the memory pointer to data location
Step 2: Get the first number from memory in accumulator
Step 3: Get the second number and add it to the accumulator
Step 4: Store the answer at another memory location
PROGRAM:
Address Opcode Label MnemonicsComments

4100 3A,00,42 LDA 4200H
Initialize HL register 4200H
4103 47 MOV B,A Transfer 1st data to A reg
4104 3A,01,42 LDA 4201H Get 2nd data in A reg
Clear C reg to accumulator for
4107 0E,00 MVI C,00H carry
4109 80 ADD B Get the sum in A reg
410A D2,0E,41 JNC AHEAD (410E) If cy=0 go Ahead
410D 0C INRC If cy=1 Increment C
410E 32,02,42 AHEAD STA 4202H Store in 4202
4111 79 MOV A,C Move the value C to A
4112 24,03,42 STA 4203H Store the content
4115 76 HLT Stop the program
Observations:
Without Carry Memory

Address Contents
Input Output 4200 05
data data 4201 02
05H 07H 4202 07
02H 00H 4203 00
Memory
With Carry
Address Contents
Input data Output data 4200 05
05H 04H 4201 FF
FFH 01H 4202 04
4203 01
RESULT:
Thus an assembly language program for 8-bit addition of two numbers were written and executed successfully
by using 8085 microprocessor.
3. SUBTRACTION OF TWO 8-BIT NUMBERS
AIM:
To write an assembly language program to subtract two 8-bit numbers.
APPARATUS REQUIRED:

ALGORITHM:
Step 2: Get the first number from memory in accumulator
Step 3: Get the second number and subtract from the accumulator
Step 4: If the result yields a borrow the content of the accumulator is complemented and 01h is added to it
Step 5: A result is cleared and the content of that register is incremented incase there is a borrow. If there is no
borrow the content of the accumulator is directly taken as the result.
Step 6: Store the answer at the next memory location.
PROGRAM:
Address Opcode Label Mnemonics Comments

4100 3A,00,42 LDA 4200H Initialize HL register 4200H
4103 47 MOV B,A Transfer 1st data to A reg
4104 3A,01,42 LDA 4201H Get 2nd data in A reg
4107 0E,00 MVI C,00H Clear C reg to accumulator for carry
4109 98 SUB B Get the difference
JNC AHEAD
410A D2,0E,41 (410E) If cy=0 go Ahead
410D 0C INRC If cy=1 Increment C
410E 2F CMA Complement of difference
410F C6,01 ADI 01H Store the result in A-reg
4111 32,02,42 AHEAD STA 4202H Store the result in memory
4115 32,03,42 STA 4203H Store the content
Observations:
Memory
Input Output Address Contents
data data 4200 05
05 4201 03
03 02 4202 02
4203 00
RESULT:
Thus an assembly language program for 8-bit subtraction of two numbers were written and executed
successfully by using 8085 microprocessor.
4. MULTIPLICATION OF TWO 8-BIT NUMBERS
AIM:
To write an assembly language program to multiply two 8-bit numbers.
APPARATUS REQUIRED:

ALGORITHM:
Step 2: Move multiple and to a register
Step 3: Move the multiplier to another register
Step 4: Clear the register
Step 5:Decrement multiplier
Step 6: Repeat step 5 till multiplier comes to zero
Step 7: The result which is in the accumulator is stored in a memory location.
PROGRAM:

4100 21,00,42 LXI 4200H Initialize HL register 4200H
4103 0E,00 MXI C,00H Clear C reg to accumulator
4105 AF XRA A Get the data in A reg
4106 46 MOV B,M Move the value M to A
4107 23 INX H Increment HL pair
4108 56 MOV D,M Move the value M to D
4109 82 REPT ADD D Add the A value to D
410A D2,0E,41 INC AHEAD (410E) If cy=0 jump ahead
410D 0C INR C Increment C reg
410E 05 DLR B Decrement B reg
410F C2,09,41 INZ REPT (4109) If cy is not 0 jump REPT
4113 77 MOV M,A Move value M to A
4115 71 MOV M,C Move the value C to M
Observations:
Memory
Input Output
Address Contents
data data
4200 02
02
4201 03
03 06
4202 06
4203 00
RESULT:
Thus an assembly language program for 8-bit multiplication of two numbers were written and executed
5. DIVISION OF TWO 8-BIT NUMBERS
AIM:
To write an assembly language program to divide two 8-bit numbers.
APPARATUS REQUIRED:

ALGORITHM:
Step 1: Load divisor and divider
Step 2: Subtract divisor from divider
Step 3: Count the number of times of subtraction which is equal to quotient
Step 4: Stop subtraction when the divider is less than that that the divisor. The divider now becomes the
remainder otherwise go to step 2
Step 5: Stop the program
PROGRAM:

4100 3A,01,42 LDA 4201H Initialize HL register 4201H
4103 47 MOV B,A Set the divisor in B-reg
4104 3A,00,42 LDA 4200H Load register 4200H
4107 0E,00 MVI C,00H Clear C reg for quotient
4109 B8 AGAIN CMP B Complement B-reg
410A DA,12,41 JC store (4112) Go to subtract if it is less
410D 90 SUB B Subtract B-reg value
410E 0C INR C Increment C reg value
JMP AGAIN
410F C3,09,41 (4109) Jump the content to AGAIN
4112 32,03,42 STORE STA 4203H Store the remainder
4116 32,02,42 STA 4202H Store the quotient in memory
Observations:
Memory
Input Output Address Contents
data data 4200 04
04 4201 02
02 02 4202 02
4203 00
RESULT:
Thus an assembly language program for 8-bit division of two numbers were written and executed successfully
by using 8085 microprocessor.
6. SORTING - ASCENDING ORDER
AIM:
To write an assembly language program to show an array of data in ascending order. The first element
of the array gives the number of data in the array.
APPARATUS REQUIRED:
 8085 microprocessor kit
 Power supply cable
ALGORITHM
Step 1: Load the count value from the memory to array and save it B-ref.
Step 2: Decrement B-ref.
Step 3: Set the pair as data array address point.
Step 4: Set C reg as counter for N-1 comparison using the data address pair.
Step 5: Load a data the array in accumulator using the data address pair.
Step 6: Increment the HL pair.
Step 7: Compare the data pointer by HL with accumulator.
Step 8: If carry flag is set live the content of the set P 10, otherwise next step.
Step 9: Exchange the content of memory pointer by HL and the accumulator.
Step 10: Decrement C-reg is Zf=0 go to stop 6 otherwise next.
Step 11: Document B-reg Z=0 go to step 3.
Step 12: Stop.
PROGRAM:
Address OP Code Label Mnemonics Comments

4100 3A,00,42 LDA 4200H load the count values in A reg
4103 47 MOV B, A get count value in B reg
4104 05 DCR B decrement B reg by one
4105 21,00,42 LOOP 2: LXI H, 4200 H set pointer to array
4108 4E MOV C, M load C- reg to pointer address
4109 0D DCR C decrement C- reg by one
410A 23 INX H increment pointer HL
410B 7E LOOP 1: MOV A, M Move it to A-reg
410C 23 INX H Increment pointer
410D BE CMP M compare A with data pointer by HL
if AL memory content go to
410E DA,16,41 IC AHEAD (4116) AHEAD
4111 56 MOV D, M if not get memory content in D-reg
4112 77 MOV M, A put the A-reg in memory
4113 2B DCX H decrement H content
4114 72 MOV M, D load mem by D-reg
4115 23 INX H Increment pntr HL pair
4116 0D AHEAD: DCR C Decrement C-reg
if C-reg content is not zero go to
4117 C2,0B,41 JNZ LOOP 1(410B) loop 1
411A 05 DCR B Decrement B-reg
If B-reg content is not zero go to
411B C2,05,41 JNT LOOP 2 (4105) loop 2
411E 76 HLT Stop the program
Observations:
Memory Data before Data after

address sorting sorting
4200 05 (count) 05 (count)
4201 08 04
4202 FA 08
4203 04 0B
4204 0B FA
4205 FF FF
Result:
Thus an assembly language program to sort an array of data in ascending order was executed
7. SORTING - DESCENDING ORDER

AIM:
To write an assembly language program to show an array of data in descending order. The first element
of the array gives the number of data in the array.
APPARATUS REQUIRED:
ALGORITHM
Step 1: Load the count value from the memory the A-reg saves in B-reg.
Step 2: Decrement B-ref.
Step 3: Set the HC pair as order data array pointer.
Step 4: Set C reg as counter for N-1 comparison using the data address pair.
Step 5: Load a data the array in accumulator using the data address pair.
Step 6: Increment the data pointer lay HC with accumulator.
Step 7: Compare the data pointer by HL with accumulator.
Step 8: If carry flag is set live the content of accumulator is smaller than memory to step
10 otherwise go to next step.
Step 9: Exchange the content of memory pointer by HL and the accumulator.
Step 10: Decrement C-reg is Zf=0 go to stop 6 otherwise next.
Step 11: Document B-reg Z=0 go to step 3 (or) to next step.
Step 12: Stop.
PROGRAM:
4100 3A,00,42 LDA 4200H load the count values in A reg
4103 47 MOV B, A get count value in B reg
4104 05 DCR B decrement B reg by one
4105 21,00,42 LOOP 2: LXI H, 4200 H set pointer to array
4108 4E MOV C, M load C- reg to pointer address
4109 0D DCR C decrement C- reg by one
410A 23 INX H increment pointer HL content
410B BE LOOP 1: MOV A, M Move it to A-reg
410C 23 INX H Increment pointer
410D BE CMP M compare A with data pointer by HL
if AL memory content go to
410E DA,16,41 IC AHEAD (4116) AHEAD
4111 56 MOV M, A Put the A reg in memory
4112 77 MOV M, A If not get mem content in D reg
4113 2B DCX H decrement H content by one
4114 72 MOV M, D load mem by D-reg
4115 23 INX H Increment pointer HL pair
4116 0D AHEAD: DCR C Decrement C-reg
if C-reg content is not zero go to
4117 C2,0B,41 JNZ LOOP 1(410B) loop 1
411A 05 DCR B Decrement B-reg
If B-reg content is not zero go to
411B C2,05,41 JNT LOOP 2 (4105) loop 2
411E 76 HLT Stop the program
Observations:
Memory Data before Data after

address sorting sorting
4200 05 (count) 05 (count)
4201 09 09
4202 04 06
4203 01 04
4204 03 03
4205 06 01
Result:
Thus an assembly language program to sort an array of data in descending order were executed
8. CODE CONVERSION - BCD TO HEX CONVERSION

Aim:
To convert the BCD number in memory to the equivalent HEX number using 8085 instruction.
Apparatus Required:
Algorithm:
Step 1: Initialize memory points to 4150H
Step 2: Get the most significant digit (MSD)
Step 3: Multiply the MSD by using repeated addition
Step 4: Add the least significance digit (LSD)
Step 5: To the result obtained in previous step
Step 6: Store the HEX data in memory
Program:
4100 21,50,41 LXI H, 4150 Initialize the mem pntr
4102 7E MOV A, M
4104 B7 ADD A MSB X2
4105 47 MOV B,A store MSB X2 in B-reg
4106 87 ADD A MSB X4
4107 87 ADD A MSB X8
4108 80 ADD B MSB X10
4109 23 INX H point to LSB
410A 86 ADD M add to form HEX
410B 23 INX H increment the pointer
411C 77 MOV M, A store the result
411D 76 HLT step the program
Observation:
Input data (BCD) 4150: 02H
4151: 09H
Output data (HEX) 4152: 01DH
Result:
Thus the program to convert BCD data to HEX was executed by using 8085 microprocessor.
9. CODE CONVERSION - HEX TO BCD CONVERSION

Aim:
To convert the HEX decimal number in to its equivalent BCD number using 8085 instruction.
Apparatus Required:
Algorithm:
Step 1: Initialize memory points to 4150H
Step 2: Get the HEX decimal number in C-reg
Step 3: Perform repeated addition
Step 4: Adjust for B00 in each step
Step 5: Store the BCD data in memory
Program:
4100 21,50,41 LXI H, 4150 Initialize the mem pntr
4103 16,00 MVI D,00 clear D for MSB
4105 AF XRA A clear the accumulator
4106 4E MOV C,M get HEX data
count the number one
4107 C6,01 LOOP2: ADI 01 by one
4109 27 DAA adjust for BCD unit
410A D2,0E,41 JNC LOOP1
410D 14 INR D
410E 0D LOOP1: DCR C
410F C2,07,41 INZ LOOP2
4112 32,51,41 STA 4151 Storethe LSB
4115 7A MOV A,D
4116 32,52,41 STA 4152 Storethe MSB
Observation:
Input data (HEX) 4150: FFH
Output data (BCD) 4151: 55H
4152: 02H
Result:
Thus the program to convert HEX data to BCD was executed by using 8085 microprocessor.
10. STEPPER MOTOR INTERFACING WITH 8051 MICRO CONTROLLER FOR CLOCKWISE
ROTATION
AIM:
To write an assembly language program for driving the stepper motor in clockwise direction.
APPARATUS REQUIRED:
 Stepper Motor
 8051 Micro Controller Kit
PROGRAM:
MEMORY ADDRESS OBJECT CODES MNEMONICS
4100 7C MOV R4. #FF
4101 FF
4102 90 START: MOV DPTR, # LOOK
UP
4103 41
4104 14
4105 78 MOV R0, #04
4106 04
4107 E0 JO: MOVX A, @DPTR
4108 C0 PUSH DPH
4109 83
410A C0 PUSH DPL
410B 82
410C 90 MOV DPTR, #FFCOH
410D FF
410E C0
410F F0 MOVX @DPTR, A
4110 DC DJNZ R4, CALL
4111 06
4112 80 HLT: SJMP HLT
4113 FE
4114 09 LOOK UP: DB 09H, 05H, 06H,
0AH
4115 05
4116 06
4117 0A
4118 7A CALL: MOV R2, #03
4119 03
411A 79 DLY2: MOV R1, #FFH
411B FF
411C 7B DLY1: MOV R1, #FFH
411D FF
411E DB DLY: DJNZ R3, DLY

411F FE
4120 D9 DJNZ R1, DLY1
4121 FA
4122 DA DJNZ R2, DLY2
4123 F6
4124 D0 POP DPL
4125 82
4126 D0 POP DPH
4127 83
4128 A3 INC DPTR
4129 D8 DJNZ R0, JO
412A DC
412B 80 SJMP START
412C D5
412D END
RESULT:
Thus the stepper motor was driven in clockwise direction.
11. STEPPER MOTOR INTERFACING WITH 8051 MICRO CONTROLLER FOR

ANTICLOCKWISE ROTATION
AIM:
To write an assembly language program for driving the stepper motor in anticlockwise direction.
APPARATUS REQUIRED:
 Stepper Motor
 8051 Micro Controller Kit
PROGRAMME
RESULT:
Thus the stepper motor was driven in anticlockwise direction.
12. TRAFFIC LIGHT INTERFACE WITH 8085 MICROPROCESSOR
AIM:
To write an assembly language program for traffic light controller interface by using 8085 microprocessor.
APPARATUS REQUIRED:
 8085 microprocessor kit

 Traffic light controller board
PROGRAM:
Address Opcode Label Mnemonics

4100 3E,80 MVI A,80
4102 D3,0F OUT 0F
4104 0E.0A L2: MVI C,04
4106 21,00,42 LXD H,4200
4109 7E L1: MOV A,M
410A D3,0C OUT 0C
410C 23 INX H
410D 7E MOV A,M
410E D3,0D OUT 0D
4110 23 INX H
4111 7E MOV A,M
4112 D3,0E OUT 0F
CALL DELAY
4114 CD,00,43 (4300)
4117 23 INX H
4118 0D DCR C
4119 C2,09,41 JNZ L1
411C C3,04,41 JMP L2
Delay program:
Address Opcode Label Mnemonics

4300 F5 PUSH PSW
4301 C5 PUSH B
4302 0E,80 MVI C,80; DELAY
4304 11,FF,FF L4 LXD D,FFFF
4307 1B L3 DCX D
4308 7A MOV A,D
4309 B3 DRA E
430A C2,07,43 JNZ L3
430D 0D DCR C
430E C2,04,43 JNZ L4
4311 C1 POP B
4312 F1 POP PSW
4313 C9 RET
Inputs:
4200 84
4201 9D
4202 24
4203 24
4204 2E
4205 49
4206 49
4207 27
4208 12
4209 92
420A 4B
420B 90
RESULT:
Thus the traffic light controller board have been interfaced and verified by using 8085 microprocessor.
13. OPEN LOOP AND CLOSED LOOP INTERFACING IN DC SERVO MOTOR
AIM:
To study the DC servo motor speed control using open loop and closed loop interfacing
APPARATUS REQUIRED:
 DC Servo Motor
 PEC16M7 Module
 Micro-4011 kit
 34-pin FRC cable
 RS-232 cable
 15 pin connector
PROCEDURE:
Switch ON power supply of the PEC16M7 module, Micro-4011and DC Motor.
 Switch ON the 12V DC ON/OFF switch.

 Switch ON the power ON/OFF switch in the PEC16M7 module.
 Press the reset switch in the PEC16M7 module and Micro-4011.
 LCD in the Micro-4011 displays as follows with a delay of few seconds.
 Select speed control.
 Select open loop.
 Set the duty cycle between (50 - 98) %
 Now the motor will start to run corresponding to the duty cycle.
 Then press the reset button.
 Add the load to the loading area and note down the speed in tabular column.
 Press reset button and select the closed loop.
 Select PID control
 Then set the speed of the motor
 Add the load to the loading area and note down the speed in tabular column.
GRAPH:
OPEN LOOP CONTROL SYSTEM
Load VS Speed
CLOSED LOOP CONTROL SYSTEM

Load VS Speed
RESULT:
Thus the DC servo motor speed control using open loop and closed loop interfacing was done and the
characteristics curves are obtained.
14. STUDY OF VARIOUS TYPES OF TRANSDUCERS
INTRODUCTION
A basic instrument system consists of three elements:
i SENSOR or INPUT DEVICE

ii SIGNAL PROCESSOR
iii RECEIVER or OUTPUT DEVICE
The input devices are all integral (e.g. a mechanical pressure gauge incorporates all of these elements). A block
diagram of a basic system is shown but they are usually more complex.
Most modern analogue equipment works on the following standard signal ranges.
· Electric 4 to 20 mA
· Pneumatic 0.2 to 1.0 bar
Older electrical equipment use 0 to 10 V. Increasingly the instruments are digital with a binary digital encoder
built in to give a binary digital output. Pneumatic signals are commonly used in process industries for safety
especially when there is a risk of fire or explosion.
The advantage of having a standard range or using digital signals is that all equipment may be purchased ready
calibrated. For analogue systems the minimum signal (Temperature, speed, force, pressure and so on ) is
represented by 4 mA or 0.2 bar and the maximum signal is represented by 20 mA or 1.0 bar.
This study material will familiarize the types of input sensors on the market today. Usually such sensors are
called PRIMARY TRANSDUCERS.
Things that we commonly measure are:

Temperature Pressure
Speed Flow rate
Force Movement, Velocity and Acceleration
Stress and Strain Level or Depth
Mass or Weight Density
Size or Volume Acidity/Alkalinity
The block diagram of a sensor is shown below.
TEMPERATURE TRANSDUCERS
THERMOCOUPLES
When two wires with dissimilar electrical properties are joined at both ends and one junction is made hot and
the other cold, a small electric current is produced proportional to the difference in the temperature. Seebeck
discovered this effect. It is true no matter how the ends are joined so the cold end may be joined at a sensitive
millivolt meter. The hot junction forms the sensor end.
RESISTANCE TYPE SENSORS
These work on the principle that the electrical resistance of a conductor change with temperature. If a constant
voltage is applied to the conductor then the current flowing through it will change with temperature. The
resistivity of the conductor change with temperature. This usually means the resistance gets bigger as the
conductor gets hotter. The following law relates the resistance and temperature.
R = Ro
o is the resistance at 0oC.
PRESSURE TRANSDUCERS
Pressure sensors either convert the pressure into mechanical movement or into an electrical output. Complete
gauges not only sense the pressure but indicate them on a dial or scale.
Mechanical movement is produced with the following elements.
· Bourdon Tube.
· Spring and Piston.
· Bellows and capsules.
 Diaphragm.
BOURDON TUBE
The Bourdon tube is a hollow tube with an elliptical cross section. When a pressure difference exists between
the inside and outside, the tube tends to straighten out and the end moves. The movement is usually coupled to a
needle on a dial to make a complete gauge. It can also be connected to a secondary device such as an air nozzle
to control air pressure or to a suitable transducer to convert it into an electric signal. This type can be used for
measuring pressure difference.
ELECTRICAL PRESSURE TRANSDUCERS
There are various ways of converting the mechanical movement of the preceding types into an electric signal.
Th following are types that directly produce an electric signal.
· Strain Gauge types.
· Piezo electric types.
· Other electric effects.
STRAIN GAUGE TYPES
The principles of electric strain gauges are covered later. Strain gauges are small elements that are fixed to a
surface that is strained. The change in length of the element produces changes in the electrical resistance. This is
processed and converted into a voltage. A typical pressure transducer would contain a metal diaphragm which
bends under pressure
PIEZO ELECTRIC TYPES
The element used here is a piece of crystalline material that produces an electric charge on its surface when it is
mechanically stressed. The electric charge may be converted into voltage. This principle is used in the pick up
crystal of a record player, in microphones and even to generate a spark in a gas ignitor. When placed inside a
pressure transducer, the pressure is converted into an electric signal.
SPEED TRANSDUCERS
Speed transducers are widely used for measuring the output speed of a rotating object. There are many types
using different principles and most of them produce an electrical output.
OPTICAL TYPES
These use a light beam and a light sensitive cell. The beam is either reflected or interrupted so that pulses are
produced for each revolution. The pulses are then counted over a fixed time and the speed obtained. Electronic
processing is required to time the pulses and turn the result into an analogue or digital signal.
TACHOMETERS
There are two types, A.C. and D.C. The A.C. type generates a sinusoidal output. The frequency of the voltage
represents the speed of rotation. The frequency must be counted and processed. The D.C. type generates a
voltage directly proportional to the speed. Both types must be coupled to the rotating body. very often the
tachometer is built into electric motors to measure their speed.
FLOW METERS
There are many hundreds of types of flow meters depending on the make and application. They may be
classified roughly as follows.
 POSITIVE DISPLACEMENT TYPES

 INFERENTIAL TYPES
 VARIABLE AREA TYPES
 DIFFERENTIAL PRESSURE TYPES
POSITIVE DISPLACEMENT TYPES
These types have a mechanical element that makes the shaft of the meter rotate once for an exact known
quantity of fluid. The quantity of fluid hence depends on the number of revolutions of the meter shaft and the
flow rate depends upon the speed of rotation. Both the revolutions and speed may be measured with mechanical
or electronic devices. Some of the most common listed below.
 Rotary piston type.
 Vane type.
 Lobe type or meshing rotor.
 Reciprocating piston type
FORCE SENSORS
The main types of force sensors are
 Mechanical types.
 Hydraulic types.
 Electrical strain gauge types.
MECHANICAL TYPES
Mechanical types are usually complete measuring systems involving some form of spring such as in a simple
spring balance or bathroom scale. It is a basic mechanical principle that the deflection of a spring is directly
proportional to the applied force so if the movement is shown on a scale, the scale represents force.
15. STUDY OF HYDRAULIC, PNEUMATIC AND ELECTRO-PNEUMATIC CIRCUITS
Fluid power may be defined as the technology that deals with the generation, control and transmission of
power using pressurized fluids.
Fluid power systems = Hydraulic systems + Pneumatic systems
Hydraulic System: The hydraulic system employs liquids such as water, petroleum oils and synthetic
oils as the fluid medium. A hydraulic system consists of six basic components. The basic components and their
functions as discussed below.
1. Reservoir: A reservoir is an oil supply tank.

2. Pump: A pump is used to force the liquid into the system.
3. Prime mover: A prime mover, usually an electric motor, is used to drive the pump.
4. Valves: Valves are fitted in the system to control liquid direction, pressure and flow rate.
5. Actuator: An actuator is provided to convert the liquid energy into mechanical force or torque to do
useful work. The actuator can be either cylinders or hydro motors.
6. Fluid transfer piping: The hydraulic piping is provided to carry the liquid from oneplace to another.
Pneumatic System: The pneumatic system employs gas, most commonly compressed air as the fluid
medium. The pneumatic systems also have similar six basic components. The basic components and their
functions are discussed below.
1. Reservoir: An air tank is provided to store the compressed air required for the operations.
2. Compressor: A compressor is used to compress the incoming atmosphere air so as to increase the
pressure of the air.
3. Prime mover: A prime mover, usually an electric motor is used to drive the compressor.
4. Valves: Valves are fitted in the system to control air direction, pressure and flow rate.
5. Actuator: An actuator is provided to convert the air energy into mechanical force or torque to do
useful work.
6. Fluid transfer piping: Piping is provided to carry the compressed air from one place to another.
Electro-Pneumatic System: The electrical control of fluid power system requires the electrical signal
from computer interface to control the machine. The electrical control devices are widely preferred due to
following uses;
1. They can be easily controlled.

2. They improve the overall control flexibility of fluid power system.
3. They provide quick and accurate control operations.
4. They require less maintenance.

5. They exhibit better reliability and have longer service life.
The most commonly used electrical control devices are:
1. Push-button switches.
2. Limit switches.
3. Pressure switches.
4. Temperature switches.
5. Solenoids.
6. Relays and
7. Timers.
Push-button switches: The push-button switch is used for starting and stopping of the machinery.
Limit switches: The limit switch is used to identify the extreme limits of the cylinder actuation.
Pressure switches: The pressure switch is used to sense a change in pressure automatically and opens or
closes an electrical switch when a predetermined pressure is reached.
Temperature switches: The temperature switch is used to sense a change in temperature automatically.
Solenoids: Solenoid is an electromagnetic mechanical transducer that converts an electrical signal into a
mechanical output force.
Relays: Relays are electrically operated switches. They offer simple ON/ OFF switching action in
response action in response to a signal issued by a control system.
Timers: Timers, also known as time-delay relays are used to control the time duration of a working
cycle.
A ladder diagram is a representation of hardware connections between switches, relays, solenoids, etc.,
which constitute the basic components of an electrical control system.
HYDRAULIC
16. SIMULATION OF HYDRAULIC SINGLE ACTING CYLINDER USING AUTOMATION STUDIO

SOFTWARE
AIM:
To simulate a hydraulic single acting cylinder using Automation Studio Software and controlling its
direction and flow.
APPARATUS REQUIRED:
 Automation Studio Software
 Single Acting Cylinder
 Flow Control Valve
 3/2 Solenoid DCV
 Pump
PROCEDURE:
 Open the Automation Studio Software.
 Draw the various components as per the circuit.
 Connect the component terminals using line command.
 Select the simulation mode.
 Choose the various positions of valves for operation of the cylinder.
NORMAL POSITION ACTUATED POSITION
RESULT:
Thus the hydraulic single acting cylinder was simulated using Automation Studio Software and its
direction and flow has been controlled.
17. SIMULATION OF HYDRAULIC DOUBLE ACTING CYLINDER USING AUTOMATION

STUDIO SOFTWARE
AIM:
To simulate a hydraulic double acting cylinder using Automation Studio Software and controlling its
direction and flow.
APPARATUS REQUIRED:
 Double Acting Cylinder
 4/2 Hand Levered DCV
 Pump
PROCEDURE:
 Draw the various components as the per circuit.
RESULT:
Thus the hydraulic double acting cylinder was simulated using Automation Studio Software and
its direction and flow has been controlled
18. SIMULATION OF HYDRAULIC MOTOR USING AUTOMATION STUDIO SOFTWARE

AIM:
To simulate a hydraulic motor using Automation Studio Software and controlling its direction and flow.
APPARATUS REQUIRED:
 Hydraulic Motor
 4/2 Hand Levered DCV
 Pump
PROCEDURE:
 Draw the various components as per the circuit.
RESULT:
Thus the hydraulic motor was simulated using Automation Studio Software and its direction and
flow has been controlled
PNEUMATICS
19.SIMULATION OF PNEUMATICS SINGLE ACTING CYLINDER USING AUTOMATION

STUDIO SOFTWARE
AIM:
To simulate a pneumatic single acting cylinder using Automation Studio Software and controlling its
direction.
.
APPARATUS REQUIRED:
 3/2 Hand Levered Spring Return DCV
 FRL Unit
PROCEDURE:
 Connect the FRL unit to the main air supply.
 Draw the other various components as per circuit.
RESULT:
Thus the pneumatic single acting cylinder was simulated using Automation Studio Software and
its direction has been controlled.
20. SIMULATION OF PNEUMATIC DOUBLE ACTING CYLINDER USING AUTOMATION

STUDIO SOFTWARE
AIM:
To simulate a pneumatic double acting cylinder using Automation Studio Software.
APPARATUS REQUIRED:
 Double Acting Cylinder
 4/2 Hand Levered Spring Return DCV
 FRL Unit
PROCEDURE:
 Choose the various positions of valves for operation of the cylinder
RESULT:
Thus the pneumatic double acting cylinder was simulated using Automation Studio Software and
.
21. SIMULATION OF PNEUMATIC SINGLE ACTING CYLINDER WITH AN IMPULSE PILOT

VALVE USING AUTOMATION STUDIO SOFTWARE
AIM:
To simulate a pneumatic single acting cylinder using Automation Studio Software with an impulse pilot
valve.
APPARATUS REQUIRED:
 Single Acting Cylinder
 3/2 Hand Levered Spring Return DCV
 3/2 Pilot Operated Spring Return DCV
 FRL Unit
PROCEDURE:
 Choose the various positions of valves for operation of the cylinder
RESULT:
Thus the pneumatic single acting cylinder with an impulse pilot valve was simulated using Automation
Studio Software.
ELECTROPNEUMATICS
22. SIMULATION OF ELECTROPNEUMATIC SINGLE ACTING CYLINDER USING

AUTOMATION STUDIO SOFTWARE
AIM:
To simulate a electro pneumatic single acting cylinder using Automation Studio Software and
controlling its direction.
APPARATUS REQUIRED:
 Input / Output Relay Box
 3/2 Solenoid Operated Spring Return Valve
 FRL Unit
PROCEDURE:
NORMAL POSITION
ACTUATED POSITION
RESULT:
Thus the electro pneumatic single acting cylinder was simulated using Automation Studio Software and
23. SIMULATION OF ELECTROPNEUMATIC DOUBLE ACTING CYLINDER USING

AUTOMATION STUDIO SOFTWARE
AIM:
To simulate a electro pneumatic double acting cylinder using Automation Studio Software and
controlling its direction.
APPARATUS REQUIRED:
 4/2 Solenoid Operated Spring Return Valve
 FRL Unit
PROCEDURE:
NORMAL POSITION
ACTUATED POSITION
RESULT:
Thus the electro pneumatic double acting cylinder was simulated using Automation Studio Software and
24. SIMULATION OF ELECROPNEUMATIC DOUBLE ACTING CYLINDER WITH DOUBLE

SOLENOID VALVE USING AUTOMATION STUDIO SOFTWARE
AIM:
To simulate an electropneumatic double acting cylinder with a double solenoid valve using Automation
Studio Software.
APPARATUS REQUIRED:
 4/2 Solenoid Operated Valve
 FRL Unit
PROCEDURE:
NORMAL
POSITION
ACTUATED POSITION
RESULT:
Thus the elctropneumatic double acting cylinder with a double solenoid valve was simulated using
Automation Studio Software.
25.STUDY OF PLC AND ITS APPLICATIONS
Programmable logic controller (PLC) is one of the important micro-processor based controllers. A
Programmable logic controller can be defined as a digital electronic device that uses a programmable memory
to store instructions and to implement functions such as logic, sequencing, timing, counting and arithmetic in
order to control machines and process. PLC is a user-friendly electronics computer designed to perform logic
functions such as AND, OR and NOT for controlling the operation of industrial equipments and process. PLC is
a solid-state digital element for making logic decisions and providing corresponding outputs. They are designed
to control fluid power systems.
Major units of a PLC: A PLC consists of three major elements, as discussed below.
1. Central processing unit (CPU)

2. Programmer/ monitor (PM) and
3. Input/ Output module (I/O)
The CPU controls and processes all the operations within the PLC. The CPU (i) receives input data from
various sensing devices such as switches, (ii) executes the stored program and (iii) delivers corresponding
output signals to various load control devices as relay coils and solenoids. It consists a microprocessor with a
fixed memory (ROM- read only memory) and a variable memory (RAM- random access memory).
The programmer/ monitor unit allows the user to enter the desired programme into the RAM. The
programme which is entered in relay logic (in RAM) determines the sequences of operation of the system to be
controlled.
The input/ output module interfaces between the fluid power system input sensing and output load
devices and the CPU. The purpose of the I/O module is to transfer the various signals received from or sent to
the fluid power interface devices such as push-button switches, pressure switches, limit switches, solenoid coils,
motor relay coils and indicator lights.
The basic internal architecture of a PLC is shown, it consists of a central processing unit (CPU)
containing the system microprocessor, memory, and input/output circuitry. The CPU is supplied with a clock
that has a frequency of typically between 1 and 8 MHz. This frequency determines the operating speed of the
PLC and provides the timing and synchronization for all elements in the system. The information within the
PLC is carried by means of digital signals. The internal paths along which digital signals flow are called buses.
The CPU uses the data bus for sending data between the constituent elements, the address bus to send the
addresses of locations for accessing stored data, and the control bus for signals relating to internal control
actions. The system bus is used for communications between the input/output ports and the input/output unit.
Ladder Programming: The basic form of programming commonly used with PLC’s is ladder programming.
PLC programming based on the use of ladder diagrams involves writing a program in a similar manner to
drawing a switching circuit. The ladder diagram consists of two vertical lines representing the power lines.
Circuits are connected as horizontal lines i.e., the rungs of the ladder, between these two verticals.
PLC Ladder Symbols
Applications of PLC: Because of the versatility of PLC, it is used in various places for automation. In
industries various processes needs to be controlled at every instant of time such as valve control, pressure
control, robotic action, etc. PLC having the ability to perform number of tasks by simply modifying the program
in a prominent device for automation of such activities. There are various places where a PLC can be used.
Some of those are listed as below.,
1. The batch processes in chemical, cement, food processing and paper processing industries which are
sequential in nature, requires time of event based decisions is controlled by PLC’s.
2. In large process plants PLCs are being increasingly used for automatic start up and shut down of critical
equipment. A PLC ensures that equipment cannot be started unless all the permissive conditions for safe
start have seen established. It also monitors the conditions necessary for safe running of the equipment
and trips the equipment whenever any abnormality in the system is detected.
3. The PLC can be programmed to function as an energy management system for boiler control for
maximum efficiency and safety.
4. In automation of blender reclaimers, bulk material handling system at ports, brick moldings press in
refractories, plastic molding process, galvanizing unit, transfer of machine tools and work transfer lines,
packaging sets.
5. In Steel industries PLC plays an important role in every procedure and machines such as controlling
temperature and pressure in boilers, lifting electrodes, feeding oxygen lances for steel, cooling the bed,
handling the fky ash content from furnace.
6. In chemical industries, handling of rock phosphate drying and grinding process.
7. In Power stations, mixing operations, modernization of boiler, turbo generator set, stored programmed
automation unit for the operation of diesel generator sets, criteria display system for equipments power,
compressed air set, gas handling etc.,
26.STUDY OF IMAGE PROCESSING TECHNIQUE
Image Processing is a technique to enhance raw images received from cameras/ sensors placed on
satellites, space probes and aircrafts or pictures taken in normal day-to-day life for various applications.
Various techniques have been developed in Image Processing during the last decades. Most of the
techniques are developed for enhancing images obtained from unmanned spacecrafts, space probes and military
reconnaissance flights. Image Processing systems are becoming popular due to easy availability of powerful
personnel computers, large size memory devices, graphics software etc._
Image Processing is used in various applications such as:
• Remote Sensing
• Medical Imaging
• Non-destructive Evaluation
• Forensic Studies
• Textiles
• Material Science.
• Military
• Film industry
• Document processing
• Graphic arts
• Printing Industry
Methods of Image Processing
There are two methods available in Image Processing.
 Analog Image Processing
Analog Image Processing refers to the alteration of image through electrical means. The most common
example is the television image. The television signal is a voltage level which varies in amplitude to represent
brightness through the image. By electrically varying the signal, the displayed image appearance is altered. The
brightness and contrast controls on a TV set serve to adjust the amplitude and reference of the video signal,
resulting in the brightening, darkening and alteration of the brightness range of the displayed image.
 Digital Image Processing
In this case, digital computers are used to process the image. The image will be converted to digital form
using a scanner – digitizer and then process it. It is defined as the subjecting numerical representations of
objects to a series of operations in order to obtain a desired result. It starts with one image and produces a
modified version of the same. It is therefore a process that takes an image into another.
The term digital image processing generally refers to processing of a two-dimensional picture by a
digital computer. In a broader context, it implies digital processing of any two-dimensional data. A digital
image is an array of real numbers represented by a finite number of bits.
The principle advantage of Digital Image Processing methods is its versatility, repeatability and the
preservation of original data precision.
Image Processing techniques
The various Image Processing techniques are:
 Image representation
 Image preprocessing
 Image enhancement
 Image restoration
 Image analysis
 Image reconstruction
 Image data compression
Image Representation
An image defined in the "real world" is considered to be a function of two real variables, for example, f(x,y)
with f as the amplitude (e.g. brightness) of the image at the real coordinate position (x,y). The 2D continuous
image f(x,y) is divided into N rows and M columns. The intersection of a row and a column is called as
pixel.The effect of digitization is shown.,
Image Preprocessing
 Scaling
The theme of the technique of magnification is to have a closer view by magnifying or zooming the interested
part in the imagery. By reduction, we can bring the unmanageable size of data to a manageable limit.
 Magnification
This is usually done to improve the scale of display for visual interpretation or sometimes to match the scale of
one image to another.
 Reduction
th th
To reduce a digital image to the original data, every m row and m column of the original imagery is selected
and displayed.
 Rotation
Rotation is used in image mosaic, image registration etc. One of the techniques of rotation is 3-pass shear
rotation, where rotation matrix can be decomposed into three separable matrices.
 Mosaic
Mosaic is a process of combining two or more images to form a single large image without radiometric
imbalance. Mosaic is required to get the synoptic view of the entire area, otherwise capture as small images.
Image Enhancement Techniques
Some times images obtained from satellites and conventional and digital cameras lack in contrast and brightness
because of the limitations of imaging sub systems and illumination conditions while capturing image. Images
may have different types of noise. In image enhancement, the goal is to accentuate certain image features for
subsequent analysis or for image display. Some of the enhancement techniques are: Contrast Stretching, Noise
Filtering, Histogram modification
 Contrast Stretching
Some images (eg., water bodies, desert dense forests, snow, clouds and under hazy conditions over
heterogeneous regions) are homogeneous i.e., they do not have much change in their levels. They are
characterized as the occurrence of very narrow peaks. The images hence obtained are not easily interpretable
due to poor human perceptibility. This is because there exists only a narrow range of gray-levels in the image
having provision for wider range of gray-levels. The contrast stretching methods are designed exclusively for
frequently encountered situations.
 Noise Filtering
Noise filtering is used to filter the unnecessary information from an image. It is also used to remove various
types of noises from the images. Various filters like low pass, high pass, mean, median etc., are available.
 Histogram Modification
Histogram reflects the characteristics of image. One such example is Histogram Equalization. Histogram
equalization is a nonlinear stretch that redistributes pixel values so that there is approximately the same number
of pixels with each value within a range. The result approximates a flat histogram. Therefore, contrast is
increased at the peaks and lessened at the tails.
Image Restoration
Image restoration refers to removal or minimization of degradations in an image. This includes de-blurring of
images degraded by the limitations of a sensor or its environment, noise filtering, and correction of geometric
distortion or non-linearity due to sensors.
Image Analysis
Image analysis is concerned with making quantitative measurements from an image to produce a description.
This task could be reading a label on a grocery item, sorting different parts on an assembly line, or measuring
the size and orientation of blood cells in a medical image.
Image Reconstruction
Image reconstruction from projections is a special class of image restoration problems where a two- (or higher)
dimensional object is reconstructed from several one-dimensional projections. Each projection is obtained by
projecting a parallel X-ray (or other penetrating radiation) beam through the object. Planar projections are thus
obtained by viewing the object from many different angles. Reconstruction algorithms derive an image of a thin
axial slice of the object, giving an inside view otherwise unobtainable without performing extensive surgery.
Such techniques are important in medical imaging (CT scanners), astronomy, radar imaging, geological
exploration, and nondestructive testing of assemblies.
Image Data Compression
Compression is a very essential tool for archiving image data, image data transfer on the network etc. They are
various techniques available for loss and lossless compressions. One of most popular compression techniques,
JPEG (Joint Photographic Experts Group) uses Discrete Cosine Transformation (DCT) based compression
technique.
Image Representation
Image Preprocessing Magnification
Reduction
Rotation
Mosaic
Image Enhancement Techniques Contrast Stretching
Noise Filtering
Histogram Modification
Image Restoration
Image Reconstruction
Image Data Compression

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www.Vidyarthiplus.

DEPARTMENT OF MECHANICAL ENGINEERING

Subject Code : ME 6712

Subject Name : MECHATRONICS

1. Prof.S.Arun. BE (Mech)., ME(CAD)

Department of Mechanical Engineering

Vel Tech (Owned By RS Trust)

2. Prof.N.K.Karthickeyan. BE (Mech)., ME (CAD)

Department of Mechanical Engineering

Vel Tech (Owned By RS Trust)

ME6712 MECHATRONICS LABORATORY LTPC

1. Assembly language programming of 8085 – Addition – Subtraction – Multiplication – Division

LIST OF EQUIPMENT FOR A BATCH OF 30 STUDENTS

Sl. No. NAME OF THE EQUIPMENT Qty.

1. INTRODUCTION TO MECHATRONICS SYSTEM

APPLICATIONS OF MECHATRONICS ENGINEERING:

Mechatronics engineering finds application in the following fields.

 Electronic home appliances

2. ASSEMBLY LANGUAGE PROGRAMMING OF 8085 ADDITION OF TWO 8-BIT NUMBERS

To write an assembly language program to add two 8-bit numbers.

 8085 Microprocessor kit

Step 1: Initialize the memory pointer to data location

Step 2: Get the first number from memory in accumulator

Step 3: Get the second number and add it to the accumulator

Step 4: Store the answer at another memory location

Address Opcode Label MnemonicsComments

Without Carry Memory

3. SUBTRACTION OF TWO 8-BIT NUMBERS

To write an assembly language program to subtract two 8-bit numbers.

 8085 Microprocessor kit

Step 1: Initialize the memory pointer to data location

Step 2: Get the first number from memory in accumulator

Step 6: Store the answer at the next memory location.

Address Opcode Label Mnemonics Comments

4. MULTIPLICATION OF TWO 8-BIT NUMBERS

To write an assembly language program to multiply two 8-bit numbers.

 8085 Microprocessor kit

Step 1: Initialize the memory pointer to data location

Step 2: Move multiple and to a register

Step 3: Move the multiplier to another register

Step 4: Clear the register

Step 5:Decrement multiplier

Step 6: Repeat step 5 till multiplier comes to zero

Step 7: The result which is in the accumulator is stored in a memory location.

Address Opcode Label Mnemonics Comments

5. DIVISION OF TWO 8-BIT NUMBERS

To write an assembly language program to divide two 8-bit numbers.

 8085 Microprocessor kit

Step 1: Load divisor and divider

Step 2: Subtract divisor from divider

Step 3: Count the number of times of subtraction which is equal to quotient

Step 5: Stop the program

Address Opcode Label Mnemonics Comments

6. SORTING - ASCENDING ORDER

Address OP Code Label Mnemonics Comments

Memory Data before Data after

7. SORTING - DESCENDING ORDER

Memory Data before Data after

8. CODE CONVERSION - BCD TO HEX CONVERSION

9. CODE CONVERSION - HEX TO BCD CONVERSION

411E DB DLY: DJNZ R3, DLY

11. STEPPER MOTOR INTERFACING WITH 8051 MICRO CONTROLLER FOR

12. TRAFFIC LIGHT INTERFACE WITH 8085 MICROPROCESSOR