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Designing with a microcontroller offers the flexibility of adding features like LCD displays, lighting LEDs, a user interface, programmability, safety features, speed control etc. Modern washing machines, for instance, offer many features over the mechanical designs of old. These features include a display that gives cycle information as well as providing a stain removal guide. These machines use microcontrollers to efficiently vary the speed of different cycles based on the content being washed.Benetits of Mechatronic Systems © More user-friendly Mechatronic systems are more user-friendly e.g. power door locks, keyless entry, cruise control etc. ¢ Precision control Flow rate, speed, position, and any number of other variables can be controlled precisely with a microcontroller. Cruise control in an automobile is a great example of how a mechatronic solution allows for precise control. In order to give the car a smooth acceleration to the desired speed as well as maintaining a constant velocity over varying load conditions.Benefits of Mechatronic Systems © More efficient The efficiency of a system can be improved by adding intelligence to the design. Certain portions of the system can be shut-off when not in use or a microcontroller can make better use of the energy available. ¢ Lower cost (in the long run) A complex mechanical solution may be simplified using a microcontroller-based approach. Design time, product size, and reliability can all be improved with a mechatronic solution.Benetits of Mechatronic Systems e Flexible design (reprogrammable) Mechatronic systems are flexible and can be easily switched to perform different jobs by simply changing the robot control program. This procedure is called "reprogramming“. © More reliable Mechanical designs are prone to wear and tear over time. For example mechanical odometers use a direct drive system that consists of a flexible cable running from the transmission to the odometer gage. The solution is unreliable because the cable is prone to failure. The modern mechatronic solution consists of an optical encoder and digital display, which increases system reliability.Benefits of —____Mechatronic Systems © Smaller size Adding a microcontroller to a system may result in space savings. ¢ Safer Adding intelligence to a system makes it safer. Whether you add an automatic shutdown to a coffee pot or sense when a system is overheating, numerous safety checks can be easily added to a system when a microcontroller is controlling the system.Automatic camera Modern cameras are fully automatic including focusing and exposure. Control system for an automatic camera ‘Switch to activate system (Operating of press button to take photographs Range sensor Interface. -[itoaraive } —G@) mor Battery test Solenoid (A) Actuator to open shutter Micro Actuator to open shutter processor control RS + Ls Light sensor Encoder to init +{ Lens position drive } (Mi) Motor [—+[ Aperture control drive} x) Stepper motor Display of data in view finder] sive lens positionWorking: o Cl) cl pct) CieecsT To take the photograph of an object with the help of the camera, the switch is pressed which activates the system. The range sensor, senses the distance of the object to be photographed and this data is input to the micro processor. The microprocessor in turn sends on output to motor drive to position the lens for focusing. The position of the lens is input to the micro processor. The light sensor sends the signal of light intensity on the object to the microprocessor. Based on this, signals are sent to control the duration of time the shutter have to be kept open. All these actions and reactions take place with in a fraction of second. Once the film has been exposed, the information is input to the microprocessor which gives output for driving the motor for advancing the film to drive and the camera is ready for the next exposure. Earlier cameras were adjusted for light, focusing and time or duration of aperture opening based on the sensitivity of the film including winding all being carried out manually.Digital cameras + In this case the image of the object taken by the cameras is converted to digital images and stored in memory housed in the camera. + As many number of photographs can be shot depending on the memory size. The photos stored in the memory can be seen on the monitor of a computer system and selection can be made. + With the help of a good printer and quality paper the photographs can be obtained. * The memory chip can be used again and only thing is it is overwritten. Also the contents of the memory chip can be transferred and then printout of selected shot can be made at leisure. + Handy cams of magnetic tape, and digital types with separate memory chip for still photographs are available in the market.Automatic washing machine + This is a sequential controlled system wherein control is exercised based on event, or are time driven i.e., control action will be executed one after another operation. + The operations to be carried out in a domestic washing machine are soaking, washing, rinsing and drying. + Each of these operations involves number of steps. Soaking involves selection of correct quantity of detergent and water based on the type and amount of cloth. + This requires opening of the valve to fill the machine drum to the required level and closing the valve once the required level of water has reached and rotating the drum one/two rotations in either direction for a pre-set amount of time during the soaking operation.* This is followed by washing which is a time event. Then the rinsing event which measures the pH value and compares it with the supply water. * This event continues till the pH value of the water in the cloth and the supply water are equal. + Finally the drying operation till the minimum percentage of moisture is retained in the cloth.In modern washing machine mechanical system is replaced by digital device i.e., a micro controller and the sequence of instruction (program embedded in the microcontroller). The amount of detergent, amount of water, pH value are all sensed by the sensor and these sensed quantities or signals are input to the microcontroller. Based on the input and the software embedded, the corresponding output of the micro controller to carry out the different sequence of operations. The sequence of contrail can be varied by varying the software embedded at the manufacturing level of the washing machine.Micro controller based washing machine (Basic Concept) Supply of Water Water Level » Pump Washing Machine Drum speed and Actuator ‘cectionEngine Management System + Engine management system is used for managing the ignition and air fuel requirements of an engine. + In the case of a four stroke multi-cylinder petrol engine, each cylinder has a piston performing all the four stroke (suction, compression, working or expansion and exhaust strokes) and the piston rod of each piston connected to a common crankshaft, and their power stroke at different times resulting in continuous power for rotation of the crankshaft. + The power and speed of an engine are functions of ignition timing and air fuel mixture. Hence, by controlling the ignition timing and air fuel mixture it is possible to control the speed and power of the engine. + In modern cars the ignition timing, opening and closing of valves at appropriate time, quality of air fuel mixture are controlled by microprocessor with the help of sensors.Engine management system using microprocessor Engine speed ———>] [-——— Spark timing Crank shaft position ———+] Micro processor —_ 4 [Solenoid air Memory fuel mixture Spark timing feed back ————+} Engine temperature ————> + vo ; devices Throttle position ————>} }-——— Fuel injection and exhaust valves Quantity of air flow ———>}+ The primary function of any machine tool is to impart the required shape and dimensions to a work piece with the desired accuracy by removing excess material from the work piece in the from of chips or particles. + A computerized or computer numerical control (CNC) is a control system that utilizes dedicated program stored computer or microcontroller to perform some or all the basic numerical control functions. + A machine tool incorporating such a control system is called CNC machine. +A CNC machine is a Mechatronics system since the machine tool which is a mechanical system is incorporated or integrated with electronic controls for its different drives and computer system for interfacing the software with the mechanical and electronic system. + Hardware or electronic circuits controls the motions of various drives.Block diagram of a CNC machine Machine toolElement of CNC Machine In order to cater for the above requirements special consideration should be exercised while designing the different elements of the CNC machine. The important elements of a CNC machine are a. Machine Structure b. Guide ways / Slide ways c. Spindle Mounting d. Drive Units (Elements of transmission and positioning of slides) e. Tool and work holding devices f. Measuring systems g. Safety Devices.Programmable Logic Controller (PLC) PLC - System Screw terminals for input lines Overview ' [eS0000088 Ee—-—— |} — £g cr Input Processing e | | ve circut ° sypply 8 3 a Commu nication | fExpansion| lconnection: [Eanes Output Processing Circuit \ SS0000 089 Paar PC for PLC Screw terminals programming for output linesApplications of Mechatronics Smart consumer products: home security, Auto focus camera, microwave oven, toaster, dish washer, laundry washer-dryer, climate control units, Automatic door openers etc. Medical: implant-devices, Robot assisted surgery etc. Defense: unmanned air, ground, and underwater vehicles, Land rover sent to mars. Manufacturing: CNC Machines, robots, Assembly units, Bottling plants etc. Automotive: Centralized door locking, Air bags, Active suspension, Cruise control, engine management, Anti Collision and safety, ete. Network-centric, distributed systems: distributed _ robotics, tele-robotics, intelligent highways etc.Home Automation ¢ Using a Microprocessor or a Programmable Logic Controller based systems —Turn on the lights at preset times — Adjust brightness — Turn on the heat at preset times or temperatures — Security systemsHome Automation Network Intelligent Home Theatre Lighting Network Smart cabinet TV/Video Networka é Applications of Mechatronics RoboticsApplications of Mechatronics The Smart WalkerApplications of Mechatronics_ Examples of Mechatronic Wheeled - RobotsExamples of Mechatronic Systems Aerial es _ RobotsExamples of Mechatronic Systems @ Legged RobotsExamples of Mechatronic Autonomous CarExamples of Mechatronic Systems Hard Drive Underwater RobotsExamples of MechatronicApplications of Mechatronics LS ATM Machine Soreen Receipt card Buttons Printer Reader SpeakerApplications of Mechatronics Traffic ControlExamples of Mechatronic Systems — Videos 1. Food Processing Systems 2. Automatic Assembly lines 3. fully-automatic led bulbs assembly line