Elements of Mechanical Engineering (22EME13/23)

Module-5

1. Insight into future mobility technology: Electric and Hybrid Vehicles, Component of Electric
and Hybrid Vehicles. Advantages and disadvantages of Electric Vehicles (EVs) and Hybrid vehicles.

2. Introduction to Mechatronics and Robotics: open-loop and closed-loop systems. Joints &
links, Robot anatomy, Applications of Robots in material handling, processing and assembly &

inspection.

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 1
Elements of Mechanical Engineering (22EME13/23)

INTRODUCTION

1. In recent years, Greenhouse gas problem increases day by day and also the gasoline fuel rate
increases nearly about 100 Rs/liters.

2. In daily life routine, public transportation is very important but the fuel rate, some people avoid
using bikes or cars. So, many automobile manufacturer and new companies put their effort to
convert the conventional vehicle into electric vehicle that provide reliable solution.

3. A vehicle is propelled with electric motors and draw power from onboard electric source is an
electric vehicle. It is more durable and mechanically simpler than gasoline vehicle. It gives more
fuel efficiency than gasoline because it does not produce emission like internal combustion engine.

4. Automobile industry is not completely moving towards pure electric cars because there is
inherent problem of existing batteries technology. For storing the electric energy, most common
storage device used in Electric vehicle is battery. It can store large amount of energy in a small
volume and weight.

5. The recent report shows that there were more vehicles running on a gasoline product in past few
years but now the report has been changed with increasing the usage of Hybrid and Electric vehicle.
Presently people are more inclined towards the Hybrid vehicle but the future will be totally based
on electrification.

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 2
Elements of Mechanical Engineering (22EME13/23)

ELECTRIC VEHICLES

Components of Electric vehicle

There are important components in electric vehicle namely,
1. Motor
2. Motor Controller
3. Battery
4. Transmission System.
5. Drivers

Fig 5.1 Components of Electric Vehicle

Motor: The main function of motor is to convert supplied electric energy current in to mechanical
energy. Brushless DC motor (BLDC) have been much focused for many motor manufacturers.
These are more effective in term of System cost, size, higher in efficiency, excellent controllability
and also power saving than other motor.

Motor Controller: Brushless DC motor does not have brush and commutator, the electric vehicle which uses
brushless DC motor has to use motor controller which helps to control various properties of motor to take
Sufficient current and voltage applied to motor.

Battery: The main function of battery is to store electric energy. Most electric vehicle uses lead
acid battery. But in new type of electric vehicles, use lithium ion batteries because it can store more
energy than lead acid battery in same physical space. The efficiency and life span of battery is far
better than other type of Batteries. .

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Elements of Mechanical Engineering (22EME13/23)

Transmission System: The transmission system transfers mechanical power from the electric
motor to drive the wheels thus the Vehicle moves.

Drivers: A mechanical drive consists of the Fuel tank (containing conventional fuels like
petrol/diesel/CNG), the Combustion Engine, the gear box and transmission to the wheels. An
electric drive consists of the Battery, an electric motor and Power Electronics for control.

Fig 5.2 Mechanical & Electrical Drives

Working of Electric vehicle

The figure 5.1 shows the simple construction of electric vehicle. It consists of battery, motor
controller, motor which is connected to the transmission system.
1. Battery is the energy source which is charged by taking electric current from the power
source or Solar Energy. (Batteries are rechargeable).
2. After that controller control the flow of energy from energy source to the motor.
3. Motor transmit the power to the wheels of the vehicle by the use of transmission system.

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 4
Elements of Mechanical Engineering (22EME13/23)

TYPES OF ELECTRIC VEHICLE

There are three type of electric vehicle;
1. Battery Electric Vehicle (BEV) 2. Hybrid Electric Vehicle (HEV) 3. Range Extended Electric Vehicle

1. Battery Electric vehicle: This consists of an electric motor which is powered by battery
connected to it. Electric motor is used for the movement in this type of vehicle. It does not
produce emission. In traffic, BEV delivers high torque to the wheels and smoother acceleration
than internal combustion Engine.

2. Hybrid electric vehicle: Hybrid electric vehicle is a combination of electric motor and new
traditional internal combustion engine. This vehicle can work with both electric and gasoline
powered vehicle. When electric motor stop giving power then switch into Fuel mode. In HEV
low speed mechanical electric motor used specifically in city traffic. When vehicle use electric
power, there is no emission.

3. Range extended electric vehicle: Range extended electric vehicle mostly designed to run by
the battery but have gasoline generator to recharge battery when charging is low.

ADVANTAGES OF ELECTRIC VEHICLE (EV)

1. No fuel, No pollution.
2. It requires less maintenance.
3. Total operation is noise free.
4. It generates high starting torque.
5. We can charge at home.
6. Less Running cost than gasoline powered vehicle.
7. It helps to save fossil fuels.

DISADVANTAGES OF ELECTRIC VEHICLE (EV)

1. It is quite expensive.
2. Not for long range travelling because availability of less number of electric charging power
station.

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 5
Elements of Mechanical Engineering (22EME13/23)

3. It requires more time for recharging the battery.

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 6
Elements of Mechanical Engineering (22EME13/23)

HYBRID ELECTRIC VEHICLE (HEV)

A hybrid electric vehicle is a type of hybrid vehicle which combines a conventional internal
combustion engine with an electric propulsion system. Or in a technical way, a Hybrid Electric
Vehicle is a type of technology which indulges both mechanical drive train and electric vehicle.
Classification of Hybrid Electric Vehicle
1. Series Hybrid 2. Parallel Hybrid 3.Series- Parallel.

Series Hybrid:

Fig 5.3 Series Hybrid Electric Vehicle

The traction power is delivered by the electric motor, while the internal combustion engine, via a
generator, produces electric power to drive the electric motor. The excess power is then stored in
the battery pack.
Disadvantage: The Internal Combustion Engine Energy is converted twice before to drive the
wheels. Thus the system is more expensive than the parallel one.

Parallel Hybrid:

Fig 5.4Parallel Hybrid Electric Vehicle

There is direct mechanical connection between Internal Combustion Engine (ICE) , Transmission
system and the wheels. In addition, this layout has an electric traction motor that drives the wheels
with the help of battery.

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 7
Elements of Mechanical Engineering (22EME13/23)

Series- Parallel Hybrid:

Fig 5.5 Series-Parallel Hybrid Electric Vehicle

The series layout and the parallel layout are merged together in order to have both
advantages.

ADVANTAGES OF HYBRID VEHICLES

1. Environmentally Friendly : One of the biggest advantages of a hybrid car over a gasoline-
powered car is that it runs cleaner and has better gas mileage, which makes it environmentally
friendly. A hybrid vehicle runs on twin powered engine (gasoline engine and electric motor) that
cuts fuel consumption and conserves energy.

2. Lighter Vehicle: Lightweight materials are used to make hybrid vehicles so that the electrical
energy will be sufficient enough to move the vehicle. This means less dependency on the gasoline
engine.

3. Braking Helps Recharge Battery: When you step on the brake pedal in a hybrid vehicle, it will
activate a mechanism which gives the battery a little extra recharge. This allows there to be more
time before the next manual recharge that you need to perform.

4. Financial Incentives: The federal government provides a tax credit to residents of any state that
own or lease HEV.

DISADVANTAGES OF ELECTRIC AND HYBRID VEHICLES

1. Expensive compare to gasoline vehicles
2. Battery replacement cost is very high
3. Battery replacement and recycling
4. Charging point convenience
5. Longer Charging Time.

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 8
Elements of Mechanical Engineering (22EME13/23)

Unit-2 - Introduction to Mechatronics & Robotics

The term "mechatronics" was first assigned by Mr. Tetsuro Mori, a senior engineer of the Japanese
company Yaskawa, in 1969.

The word, mechatronics is composed of mecha from mechanics and tronics from electronics. In
other words, technologies and developed products will be incorporating electronics more and more into
mechanisms.

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.”

Classification mechatronic System

The two types of control systems are the open-loop control system and the closed-loop control systems.

1. Open-loop system: Open loop system is kind of system, where the output doesn’t change the
action of the system. It doesn’t have any feedback. ( Fig 5.6)

Fig 5.6 Open loop Control System

Advantages of open loop system

1. Very Simple in Construction

2. Needs low Maintenance
3. Quicker in Response
4. Inexpensive.
5. System is stable

Disadvantages of open loop system

1. Output is not accurate since no Feedback system.

2. Not Much Reliable.

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 9
Elements of Mechanical Engineering (22EME13/23)

3. Calibration is not easy.

2. Closed-loop control system: The closed-loop control system can be defined as the output of the
system that depends on the input of the system. This control system has one or more feedback loops among
its input & output. .( Fig 5.7) This kind of system produces the error signal and it Shows main difference
between the output and input of the system.

Fig 5.7 Closed loop Control System

Advantages of Closed loop system

1. System output is More Accurate.

2. Feedback Controls the error & Gives Required output
3. Calibration is easy.

Disadvantages of Closed loop system

1. Very Complex in Construction

2. Needs Maintenance
3. Slow in Response
4. Very expensive.
5. System is less stable

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 10
Elements of Mechanical Engineering (22EME13/23)

Real Time applications of open loop Systems

1. Sprinkler used to water lawn: The system is calibrated for fixed area & water valve is opened for
sprinkling purpose, but No further valve Adjustments made.

2. Automatic Toaster System: Quality of toast is dependent upon time calibrated; Depending upon
time setting bread is simply heated. The toast Quality is judged by user & has no effects on
Inputs.

Automatic Toaster System

3. Traffic light Controller: Traffic control road is dependent upon time the traffic on road becomes
mobile or Stationary depending on sequence of lamp glow. Sequence & Time are controlled by
relays (pre-determined) & Not dependent on rush on road.
Traffic light Controller

4. Automatic Washing Machine: Washing of clothes dependent on time calibrated & sequence of
operation, the output expected is cleanliness of clothes. If not clean will not be cleaned again.

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 11
Elements of Mechanical Engineering (22EME13/23)

Automatic Washing Machine

Real Time applications of Closed loop Systems

1. Speed control of an automobile :

a. The driver observes the speedometer, and based on the speed shown by the speedometer he decides
whether the fuel supply should be increased or decreased or gear change is to be made. ( Feed back)
b. A feedback signal from the eye compares the desired speed in the memory of the driver.
c. Error signals are given to brain. Brain manipulates the error signals and gives it ton hand and leg
and increase the fuel.

Speed control of an automobile

2. Water level control of overhead tanks :

a. The overhead tank has a fixed float (sensor) fixed at the desired height inside the tanks.
b. When the level of water in the tank falls, the float moves down and makes contact with fixed
contactor and circuit is closed and pump is switched ON.
c. When the level of water rises the float moves up and breaks the circuit and pump is switches OFF.
Thereby the required level of water is maintained in overhead tank.

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 12
Elements of Mechanical Engineering (22EME13/23)

Water level Controller

3. Automatic Electric Iron :

a. Thermostat senses the actual Temperature of iron

b. If temperature is beyond particular value relay switches off the supply to device
c. Maintains constant temperature

Automatic Electric Iron

Comparison between Open loop & closed loop system

Open Loop System Closed-Loop System

In this system, the controlled action is free from
the output
This system is also called a Non feedback control
system
The construction of this system is simple
The consistency is non-reliable
The accuracy of this system mainly depends on
the calibration
The stability of these systems are stable
The response is fast
The calibration of this system is difficult
The disturbance of this system will be affected
These systems are non-linear
In this system, the output mainly depends on the
controlled act of the system.
This type of control system is also called a feedback
control system
The construction of this system is complex
The consistency is reliable
The accuracy of this system mainly depends on the Feed
back.
The stability of these systems are less stable
The response is slow
The calibration of this system is easy
The disturbance of this system will  not be affected
These systems are linear

Introduction to Robotics
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Elements of Mechanical Engineering (22EME13/23)

Robots: Robots are Programmable, Multifunctional devices that are designed to move parts, tools and
Specified devices or to do work.

Robotics: Robotics is defined as study of Designing & developing of Robots for Automatic Manufacturing
& Non- Manufacturing applications.

Tasks Performed by Robots

1. Picking Hot Materials.
2. Loading& Unloading
3. Rescue operations
4. Holding & Moving Heavy Devices.
5. Placing Job on Work table.

Robot Anatomy

Simple robot construction is shown in fig 5.8 which consists of following parts
1. Base
2. Links
3. Joints
4. End Effectors.

Fig 5.8 Robot Anatomy

1. Base: Support for Robot arm is Base
2. Links: Rigid Member which connects joints link can be input or output link. Input link causes
various motions to output links.
3. Joints: Joints is which Integrates 2 or more links for relative motions.
4. End Effectors: Device at end of Robot arm which is shaped like human hand (or) Special tool
upon applications. Ex. grippers can be used as end effectors.

Types of Joints
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Elements of Mechanical Engineering (22EME13/23)

a) Linear joint (type L joint)

The relative movement between the input link and the output link is a translational sliding motion, with the
axes of the two links being parallel.

b) Orthogonal joint (type U joint)

This is also a translational sliding motion, but the input and output links are perpendicular to each
other during the movement.

c) Rotational joint (type R joint)

This type provides rotational relative motion, with the axis of rotation perpendicular to the axes of the
input and output links.

d) Twisting joint (type T joint)

This joint also involves rotary motion, but the axis or rotation is parallel to the axes of the two links.

e) Revolving joint (type V-joint, V from the “v” in revolving)

In this type, axis of input link is parallel to the axis of rotation of the joint. However the axis of the output
link is perpendicular to the axis of rotation.

Classification based on Physical configurations

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 15
Elements of Mechanical Engineering (22EME13/23)

1. Cartesian configuration
2. Cylindrical configuration
3. Polar/Spherical configuration
4. Jointed-arm/Revolve configuration

1. Cartesian configuration :
a. This Type of robot has 3 linear motions.
b. One Linear joint (L) & 2 Orthogonal joint (O). – L,O,O
c. It has 3 Mutually Perpendicular Axis.
d. Rectangular Work space can be seen in this type of Robots.
e. This Robot is also called as Rectilinear Robot/ X-Y-Z Robot/ Gantry Robot.
Features of Cartesian Robot.
a. Provides Rectangular Work space
b. Arm movement is limited
c. High Precision & accuracy
d. Carries Heavy Loads
Applications: Use to lift and move heavy loads, Pick & Place Arrangement.

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Elements of Mechanical Engineering (22EME13/23)

Cartesian configuration

2. Cylindrical configuration :
a. This Type of robot has TLO Joints
b. One Linear joint (L), Orthogonal joint (O) & Twisting Joint (T) – T, L, O.
c. Orthogonal slides which allow the arm to move up/down & in/out with respect to
the body.
d. Cylindrical Work space can be seen in this type of Robots.
e. This Robot is also called as Cylindrical Robot.
Features of Cylindrical Robot.
a. Provides more work space than Cartesian Robots.
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Elements of Mechanical Engineering (22EME13/23)

b. Mechanical design is less complex than Cartesian robots

c. Needs complex control system
d. Low Precision & accuracy
Applications: Use to lift and move heavy loads, Pick & Place Arrangement, Machine loading & Unloading,

Cylindrical configuration

3. Spherical configuration :
a. This Type of robot has TRL Joints
b. One Linear joint (L), Rotary joint (R) & Twisting Joint (T).
c. The robot has a rotary base and a pivot that can be used to raise and lower a
telescoping arm.
d. The workspace within which This Robot can move is a partial sphere.
e. This Robot is also called as Polar Configuration Robot.

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Elements of Mechanical Engineering (22EME13/23)

Features of Polar configuration Robot.

a. Good accuracy and resolution.
b. Larger Work space Compare to Cartesian &
cylindrical robots.
c. Simple in design
d. Less vertical movement
Applications: Machining, spray painting, Die casting,

Spherical configuration
4. Jointed Arm configuration :
a. This Type of robot has TRR Joints
b. Two Rotary joint (R) & Twisting Joint (T).
c. The robot resembles like human arm.
d. The workspace within which This Robot can move is a Quasi spherical space
Features of Jointed arm configuration Robot.
a. Flexibility to reach over or under an object.
b. Versatile Configuration
c. Larger Work space
d. Complex Programming
e. Less stable.
Applications: Pick & Place arrangement, spray
painting, welding
Automatic assembly.

Jointed arm configuration

Applications of Robot

I. Material Handling Applications

1. Pick-and-place operation:
i. The basic operation in this category is the relatively simple here it picks an object from one
location & places in another location.
ii. This application needs a low-technology robot of the cylindrical coordinate type.

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Elements of Mechanical Engineering (22EME13/23)

2. Stacking and insertion operation :

i. In the stacking process the robot places flat parts on top of each other, where the vertical
location of the drop-off position is continuously changing with cycle time.
ii. In the insertion process robot inserts parts into the compartments of a divided carton Boxes.

3. Machine loading and/or unloading:

Robot transfers parts into and/or from a production machine.
i. Machine loading in which the robot loads parts into a production machine, but the parts are
unloaded by some other means. Example: A press working operation

ii. Machine unloading in which the raw materials are fed into the machine without robot
assistance. The robot unloads the part from the machine assisted by vision or no vision.
Example: bin picking, die casting, and plastic moulding.

iii. Both Machines loading and unloading that involves both loading and unloading of the
work parts by the robot. The robot loads a raw work part into the process ad unloads a
finished part. Example: Machine operation, Forging, Heat Treatment.

II. Processing Applications

Robot performs a processing procedure on the part. The robot is equipped with some type of
process tooling as its end effectors.
Industrial robot applications in the processing operations include:
i. Spot welding
ii. Continuous arc welding
iii. Spray painting
iv. Metal cutting and deburring operations
v. Various machining operations like drilling, grinding, laser and water jet cutting, and riveting.
vi. Rotating and spindle operations
vii. Adhesives and sealant dispensing

III. Assembly & Inspection

1. Assembly: Combination of two or more parts to form new object is called as Assembly. This
process of assembly is done by robots.

2. Inspection: Separation of Poor quality products from good ones. This is done by 3 methods

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 20
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i. Part being measured using Instruments.

ii. Robotic vision using similar image by specified tolerance.
iii. Using laser or infrared resources.

Advantages

1. Cost-Effectiveness
2. Improved Quality Assurance
3. Increased Productivity
4. Work In Hazardous Environments
5. Less time to complete jobs assigned.

Disadvantages
1. Potential Job Losses
2. Skilled staff required to operate robots.
3. Investment Costs is high
4. Lack of emotions.

INSIGHT INTO FUTURE MOBILITY TECHNOLOGY

1. What is hybrid Vehicles? How they are different from conventional Gasoline vehicles.
2. List the Advantages of Electric vehicles compare to conventional vehicles.
3. Describe how hybrid vehicles are differ from Electric vehicles.
4. With help a line diagram describe the working principle of Electric vehicle

Mr. Praveen D.N., Assistant Professor, Dept. of Mechanical Engineering, A.I.T., Tumakuru Page 21
Elements of Mechanical Engineering (22EME13/23)

INTRODUCTION TO MECHATRONICS

1. Differentiate between open loop and close loop System

2. With Suitable Example explain the concept of open and closed loop System.
3. Illustrate the working of an washing machine to demonstrate the Mechatronics system

INTRODUCTION TO ROBOTICS

1. Define Robot and Robotics; List its advantages & disadvantages.

2. With suitable sketches , Explain the different types of Robot configurations
3. Describe about Robot anatomy.
4. Write a note on Joints of Robots.
5. List & Explain the applications of Robots.

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