The Role of Sensors in Mechatronics

Systems
CNC –Position and Speed Sensors
By
Dr. Mohamed E. H. Eltaib
Mechanical Engineering Department
 Computer Numerically (CNC Machine)
Controlled Machine Tools
o Machine Tools for metal cutting are power –
driven machines that remove metal in the form
of chip to make a finished part according to the
required geometry.

Turning operations Milling operations

Computer Numerically (CNC Machine)
Controlled Machine Tools

Overall function
“remove metal in the form of chip to make a finished part
according to the required geometry”

Main function #1 Main function #2 Main function #3

holding the WPs holding the tool achieving the required

to be machined relative motion to generate
the part geometry required
Examples of mechatronics systems (manufacturing)

a 5-axis CNC machine can cut an

Impeller blade out of metal block

Computer numerically controlled machine (5-axis CNC)

4 Dr Eltaib - KU 11/25/2022
Traditional Design V Concurrent Design
The mechanical structure is designed first, and then fitted
with off-the-shelf electric motors, drive electronics,
Traditional- gearheads and sensors. Finally a control system is
(Sequential or designed and optimized for the already existing physical
system.
series) Such a design method, that doesn’t consider aspects from
Design Approach a control point of view during the design of the physical
system, is unlikely to result in a system with optimal
control performance.

Mechanical
Control Design
Design

Parallel or concurrent Design Approach

Mechanical the entire system is treated
Design concurrently in an integrated
manner by a multidisciplinary
team of engineers and other
professionals resulting in
Control Design product with more synergy.
Dr Eltaib - KU
Synergistic Effects in Mechatronic Systems

The synergistic effects that can be achieved from integration

may be illustrated by highlighting the following aspects:-

 Creating new functionalities

 Increasing the level of autonomy and intelligence

 Achieving high performance
 Achieving a variety of features such as precision, low
cost, and miniaturization, etc.

Dr Eltaib - KU 11/25/2022
 Synergistic effect in CNC machine tools
• Machining complex shapes
• Achieve high accuracy
• Achieve high productivity

Example
Process of manufacturing turbine blades for pump or aircraft on
CNC high-precision metalworking machine
Feed drive mechanism with a lead screw (or ball screw) drive
Motor Coupling
𝑆
guidway
𝑛 𝑛

Lead The role of lead-screw and nut mechanisms

screw convert rotary motion of motor shaft into
translational motion of machine table

The ratio of the linear motion to the rotational

.motion is specified by the lead of the screw

Rotary to translational motion
conversion mechanism:
lead-screw or ball-screw with
linear guide bearings.
𝑆=𝑛× 𝐿
S=linear displacement of table
n= no of revolution of lead screw
L= lead of the lead screw (=pitch for single start screw)
Lead is the distance moved by on turn of the lead screw
 Feed drive mechanism with a lead screw (or ball screw) drive

Angular Incremental Train of

displacement Encoder pluses

Functional block diagram of incremental encoder

Main elements of incremental encoder

CNC machine tool is an example of a mechatronics system in manufacturing applications
a) True
b) False

In the design process of a CNC machine, the mechanical structure and the controller are
designed and optimized concurrently
c) True
d) False

CNC machine is a mechatronics system because it is designed based on a sequential

(series) design approach
e) True
f) False

Why a CNC machine is identified as a mechatronics system?

List three synergistic effects generated due to the parallel design of CNC machine tools.

What is the role of “the ball screw and nut mechanism” in the CNC machine tool?

What is the role of the encoder in the CNC machine tool?