Chapter 5 & 6

Adama Science and Technology
University
SoMCME
Department of Design and Manufacturing
Introduction to Mechatronics (MEng4204)

By: Tesfaye Olana (MSc)
(Design of Mechanical Systems, Mechanical Engineer)

tesfitti2016@gmail.com
2021, Adama
Chapter 5
Mechatronics System Design
08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 2

Design of mechatronics System
Stages in designing mechatronics

systems
• The design of mechatronics
systems can be divided into a
number of stages
• The various possible

solutions are evaluated and Optimization
the most suitable solution is
selected

Cont.
The need
• The design process starts with the need of a customer.
• By adequate market research and knowledge, the
potential needs of a customer can be clearly identified.
• In some cases, company may create a market need but
failures are more in this area.
• Hence, market research technology is necessary

Analysis of the problem
• This is the first stage and also the critical stage in the
design process.
• After knowing the customer need, analysis should be
done to know the true nature of the problem.
• To define the problem accurately, analysis should be
done carefully
Preparation of specification
• The second stage of the mechatronic process involves in
the preparation of a specification
• The specification must be given to understand the
requirements and the functions to be met.
• The specification gives mass dimensions, types,
accuracy, power requirements, load, praying
environments, velocity, speed, life etc.
Conceptualization
• The possible solution should be generated for each of the
functions required
• It is generated by verifying the old problems or some
newly developed techniques may be used
Optimization
• This stage involves in a selection of a best solution for
the problem
• Optimization is defined as a technique in which a best
solution is selected among a group of solutions to solve a
problem.

Detail design
• Once optimizing a solution is completed, the detail design
of that solution is developed.
• This may require a production of prototype etc.
• Mechanical layout is to be made whether physically all
component can be accommodated.
• Also whether components are accessible for
replacement /maintenance are to be checked.
Production of working drawing
• The selected design or solution is then translated into
working drawings, circuit diagrams, etc. So that the item
can be made
• Drawings also include the manufacturing tolerances for
each component
Traditional approach
• A common approach is as follows: first the mechanical parts

are designed (skeleton) followed by electrical systems
(muscles), electronic systems (sensors and nervous system)
and finally a control system (brain).
• A resulting system that appears to be Mechatronic is only a
result of application of existing solutions and corresponding
technologies.
• Research and development of new technologies is not
needed if the traditional methodology is used

Mechatronics approach
• The Mechatronic System Design Process addresses these

challenges.
• Through system modelling and simulation, it facilitates:
• understanding the behaviour of the proposed system
concept;
• optimizing the system design parameters;
• developing optimal control algorithms, both local and
supervisory;
• testing control algorithms under various scenarios ; and
• qualifying the production controller with a simulated
version of the plant running in real time (hardware-in-
the-loop testing), before connecting to the real plant.
Cont.
• The Mechatronic System Design Process provides an

environment that is rich with numerical and graphical
analysis and design tools that stimulate innovation and
cooperation within design teams.
• It aims to reduce the risk of not meeting the functional
requirements by enabling early and continuous verification
throughout the entire design workflow

Traditional Approach vs Mechatronics
Approach
Traditional approach Mechatronics approach

• Complex Mechanisms • Simple Mechanisms
• It uses conventional • It uses Hybrid components
components • Flexible control
• Conventional control • More complexity
• Less complexity • System Response is high
• Project Lead time is Less
• System Response is low
• Project Lead time is more

CASE STUDY
• Study the following mechatronics system design and

their working principles
• Wind screen wiper
• Pick and place robot
• Automatic car parking system
• Engine management system
• Engine speed sensor
• Wireless surveillance Balloon
• Communication modules
• Autonomous mobile robot and etc.

Chapter 6
Introduction to Data Acquisition
Analogue signals
• Analogue signals are free from discontinuities and can take

an infinite number of values
• They have been used since the 19th century
e.g. in telephone and wireless communication
• Perhaps the simplest form is where a voltage represents the
amplitude of some physical quantity

Cont.
For example, thermocouple signals have very small voltage
levels that must be amplified before they can be digitized.
Other sensors, such as resistance temperature detectors
(RTDs), thermistors, strain gages, and accelerometers, require
excitation to operate. All of these preparation technologies are
forms of signal conditioning.

Hardware devices in ADC conversion
• Analogue to digital conversion

Features of an ADC
• Sampling rate – rate at which continuous analog signal

is polled e.g. 1000 samples/sec
• Quantization – divide analog signal into discrete levels
• Resolution – depends on number of quantization levels
• Conversion time – how long it takes to convert the
sampled signal to digital code
• Conversion method – means by which analog signal is
encoded into digital equivalent
Example – Successive approximation method

Analog to digital conversion
Sampling
• It is the conversion of a continuous time signal into a
discrete time signal obtained by taking samples of the
continuous time signal at discrete time instants.
• It is the input to the sampler, the output to the sampler,
the output is sampling interval
Quantization
• It is the conversion of a discrete time continuous valued
signal into a discrete valued (digital) signal the value of
each signal sample is represented by a value selected
from a finite set of possible values

Cont.
• The difference b/n the in quantized sample x(n) and the

quantized output is called quantization error
Coding
• In the coding process each discrete value is represented
by a b-bit binary sequence

ADC process
• A digital signal is an approximation of an analog

one
• Levels of signal are sampled and converted to a
discrete bit pattern.
• Resistor networks can be used to convert digital
signals into analogue voltages

Digital to analogue conversion
A DAC is a Digital to Analog converter. It converts a binary
digital number into an analog representation, most
commonly voltage though current is also used sometimes.
1 0 0 0 1 1 1
0 1 0 1 0 0 0
0 0 1 1 0 1 1 DAC
1 1 1 1 1 0 1

Purpose
• To convert digital values to analog voltages

• Performs inverse operation of the Analog-to-Digital
Converter (ADC)
• Output voltage proportional to Digital Value

Typical Output
• DACs capture and hold a number, convert it to a

physical signal, and hold that value for a given
sample interval. This is known as a zero-order hold
and results in a piecewise constant output.
DAC
Output typical of a real,

Ideally Sampled Signal practical DAC due to
08/16/2021 sample & hold
By: Tesfaye Olana ASTU 2021 G.C. 23
DACs
Types
• Binary Weighted Resistor
• R-2R Ladder
• Multiplier DAC
• The reference voltage is constant and is set by the
manufacturer.
• Non-Multiplier DAC
• The reference voltage can be changed during
operation.
Characteristics
• Comprised of switches, op-amps, and resistors
• Provides resistance inversely proportion to significance
of bit
Binary Weighted Resistor DAC
• Utilizes a summing op-amp circuit

• Weighted resistors are used to distinguish each bit
from the most significant to the least significant
• Transistors are used to switch between Vref and
ground (bit high or low)

Cont.
Vref
• Ideal Op-amp V1 R
• No current into V2 2R I Rf
op-amp V3 4R -
Vout
• Virtual ground at +
Vn 2n-1R
inverting input
• Vout= -IRf MSB
 V1 V2 V3 Vn  LSB
Vout   IRf   Rf      n -1 
 R 2R 4R 2 R

Advantage and disadvantage
Advantage
• Easy principle/construction
• Fast conversion
Disadvantages
• Requirement of several different precise input resistor
values: Requires large range of resistors (2048:1 for
12-bit DAC) with necessary high precision for low
resistors one unique value per binary input bit. (High
bit DACs)
• Larger resistors ~ more error.
• Precise large resistors – expensive.
Summing OP-Amps
• Inverting summer circuit used in Binary Weighted

Resistor DAC.
• V(out) is 180° out of phase from V(in)

R-2R Resistor Ladder DAC
Vref
MSB LSB
Bit: 0 0 0 0
Vout
4-Bit Converter

Example
Vref
• Convert 0001 to analog

Cont.
V1 V0 V1 V0
=
V1  V0 V0
 V1  2 V0
R R
1
Nodal Analysis
Req  R
 2R  1
  2R 
1
Likewise,
R 1 R 1
Voltage Divider V1  V2  V2 V2  V3  V3
RR 2 RR 2
Conversion equation
 1 1 1 1
Vout  Vref  b3  b2  b1  b0 
 2 4 8 16 
For a 4-Bit R-2R Ladder
n
For general n-Bit
1
R-2R Ladder
Binary Weighted Vout  Vref  bni i
Resister DAC
i 1 2
R-2R DAC summary
• Advantages
• Only two resistor values
• Does not need as precision resistors as Binary weighted
DACs
• Cheap and Easy to manufacture
• Disadvantages
• Slower conversion rate

Performance specification
Reference
Resolution
Voltages
Settling
Linearity
Time
Speed Errors

Resolution
• The change in output voltage for a change of the

LSB.
• Related to the size of the binary representation of
the voltage. (8-bit)
• Higher resolution results in smaller steps between
voltage values
Vref
Resolution  n
2

Reference Voltage
• Multiplier DAC
• Reference voltage is a constant set by the manufacturer
• Non-Multiplier DAC
• Reference voltage is variable
• Full scale Voltage

• Slightly less than the reference voltage (Vref-VLSB)

Speed
• Also called the conversion rate or sampling rate

• rate at which the register value is updated
• For sampling rates of over 1 MHz a DAC is

designated as high speed.
• Speed is limited by the clock speed of the

microcontroller and the settling time of the DAC

Settling Time
• Time in which the DAC output settles at the desired

value ± ½ VLSB.
• Faster DACs decrease the settling time

Linearity
• Represents the relationship between digital values

and analog outputs.
• Should be related by a single proportionality
constant. (constant slope)

DAC Error
Differential
Non-Linearity
Integral
DAC Error
Gain Error
Offset Error
Monotonicity
Resolution

Non Linearity
• Deviation from a linear relationship between digital

input and analog output.
Desired
Output
Analog Output
Voltage
Digital Input
Cont.
• Differential
• Worst case deviation from the ideal VLSB step for an
increment of LSB
• Integral
• Worst case deviation from the line between the endpoint
(zero and full scale) voltages
Analog Output Voltage
Analog Output Voltage

Integral
Non-linearity
2VLSB
VLSB
Digital Input Digital Input

Gain Error
• Also called Full-Scale Error
• Deviation from the ideal full scale voltage due to a
higher or lower gain than expected.
High Gain
Desired/Ideal
Analog Output
Output
Voltage
Low Gain
08/16/2021 Digital Input

Offset error
• Also called Zero Error

• Difference between ideal voltage output and actual
voltage output for a digital input of zero.
Output
Voltage
Ideal Output
Digital
08/16/2021 Input
Monotonicity
• Increases or decreases of the digital value must

correspond to increases or decreases of the voltage
output. Desired
Output
Analog Output
Voltage
Digital Input
Resolution error
• For matching curves over time or simply outputting

accurate values a proper resolution must be selected
• Resolution must be high enough for the desired
precision (½ Vout
VLSB)
Desired Analog
signal
11
10
01
00
08/16/2021 TimeASTU 2021 G.C.

By: Tesfaye Olana 46
Common application
• Generic use Generic use
• Circuit Components
• Digital Audio Circuit Components
• Function Generators/Oscilloscopes
• Motor Controllers
Motor Controllers Digital Audio
Function
Generators/Oscilloscopes

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Adama Science and Technology

Introduction to Mechatronics (MEng4204)

(Design of Mechanical Systems, Mechanical Engineer)

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 2

Stages in designing mechatronics

• The various possible

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 3

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 4

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 6

• A common approach is as follows: first the mechanical parts

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 8

• The Mechatronic System Design Process addresses these

• The Mechatronic System Design Process provides an

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 10

Traditional approach Mechatronics approach

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 11

• Study the following mechatronics system design and

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 12

• Analogue signals are free from discontinuities and can take

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 14

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 15

• Analogue to digital conversion

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 16

• Sampling rate – rate at which continuous analog signal

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 17

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 18

• The difference b/n the in quantized sample x(n) and the

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 19

• A digital signal is an approximation of an analog

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 20

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 21

• To convert digital values to analog voltages

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 22

• DACs capture and hold a number, convert it to a

Output typical of a real,

• Utilizes a summing op-amp circuit

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 25

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 26

• Inverting summer circuit used in Binary Weighted

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 28

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 29

• Convert 0001 to analog

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 33

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 34

• The change in output voltage for a change of the

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 35

• Full scale Voltage

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 36

• Also called the conversion rate or sampling rate

• For sampling rates of over 1 MHz a DAC is

• Speed is limited by the clock speed of the

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 37

• Time in which the DAC output settles at the desired

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 38

• Represents the relationship between digital values

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 39

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 40

• Deviation from a linear relationship between digital

Analog Output Voltage

Digital Input Digital Input

08/16/2021 By: Tesfaye Olana ASTU 2021 G.C. 42

08/16/2021 Digital Input

• Also called Zero Error