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Mechatronics
(MECHATS)

Lesson 3:
Mechatronics
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TOPIC
1.Mechatronics
2.Mechatronics Design Process
3.Evolution of Mechatronics
4.Elements of Mechatronics
5.Mechatronics Application
6.Relay Logic Diagram
7.Relay Logic Diagram Design
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Topic 1: Mechatronics

▪ The name [mechatronics] was coined by Ko

Kikuchi, now president of Yasakawa Electric Co.,
Chiyoda-Ku, Tokyo.
▪ MECHA + TRONICS = MECHATRONICS
▪ Integration of electronics, control engineering, and
mechanical engineering.
▪ Synergistic integration of mechanical engineering
with electronics and intelligent computer control
in the design and manufacturing of industrial
products and processes.
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Topic 1: Mechatronics

Disciplinary Foundation of Mechatronics

▪ Mechanical Engineering
▪ Electrical Engineering
▪ Computer Engineering
▪ Computer/Information Systems
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Process
Mechatronics Design Process
1. Modeling/Simulation
2. Prototyping
3. Deployment/Life cycle
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Process
 Topic 2: Mechatronics Design
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Process
▪ Modeling: Block diagram or visual interface
for creating intuitively understandable
behavioral models of physical or abstract
phenomenon. The ability to encapsulate
complexity and maintain several levels of
subsystem complexity is useful.
▪ Simulation: Numerical methods for solving
models containing differential, discrete,
hybrid, partial, and implicit nonlinear (as well
as linear) equations. Must have a lock for
real-time operation and be capable of
executing faster than real time.
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Process
▪ Design: Numerical methods for constrained
optimization of performance functions based
on model parameters and signals.
▪ Analysis: Numerical methods for frequency-
domain, time-domain, and complex-domain
design.
▪ Real-Time Interface: A plug-in card is used to
replace part of the model with actual
hardware by interfacing to it with actuators
and sensors. This is called hardware in the
loop simulation or rapid prototyping and must
be executed in real time.
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Process
▪ Code Generator: Produces efficient high-level
source code from the block diagram or visual
modeling interface. The control code will be
compiled and used on the embedded
processor. The language is usually C.
▪ Embedded Processor Interface: The
embedded processor resides in the final
product. This feature provides communication
between the process and the computer-aided
prototyping environment. This is called a full
system prototype
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Topic 3: Evolution of Mechatronics

▪ Technological advances in design,

manufacturing, and operation of engineered
products/devices/processes can be traced
through:
a. Industrial revolution
b. Semiconductor revolution
c. Information revolution
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Topic 3: Evolution of Mechatronics

Industrial Revolution
▪ Mechanical Designs
1. Float valves, or ballcocks - are used to
regulate fluid levels in tanks. In addition to
the valve body, a typical float valve has a
spherical or similarly shaped hollow ball
attached to the valve through a lever or arm.
The ball, or “float,” rides on, near, or beneath
the surface of the fluid and its up and down
motion is transferred mechanically to the
valve, opening it or closing it, depending on
the position of the float with respect to the
tank. Float valves are employed to create
completely mechanical level control
systems.
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Topic 3: Evolution of Mechatronics

Industrial Revolution
▪ Mechanical Designs
2. Watt’s Flyball Governor - an
early example of an automatic
control system consisting of an
error sensor connected by a
negative feedback loop to a
control device which drives the
error to zero thus maintaining a
desired operating point.
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Topic 3: Evolution of Mechatronics

Industrial Revolution
▪ Mechanical Designs
3. Cam Operated Switch -
mechanical power switches. It
works by manually turning the
hand lever or control knob in a
rotary cam switch.
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Topic 3: Evolution of Mechatronics

Industrial Revolution
▪ Mechanical Designs
4. Bi-metallic Strip - A bimetallic strip consists
of two different materials with different
expansion coefficients that are bonded together.
For example, for brass and steel, the
coefficients of linear expansion are:
Brass: 19 x 10-6 /°C Steel: 11 x 10-
6
/°C
When this bimetallic strip is heated, the brass
expands more than the steel and the strip
curves with the brass on the outside. If the strip
is cooled, it curves with the steel on the outside.
Bimetallic strips are used as switches in
thermostats.
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Topic 3: Evolution of Mechatronics

Semiconductor Revolution
▪ Led to the creation of integrated circuit (IC)
technology.
▪ Effective, miniaturized, power electronics
could amplify and deliver needed amount
of power to actuators.
▪ Signal conditioning electronics could filter
and encode sensory data in analog/digital
format.
▪ Hard-wired, on-board, discrete
analog/digital ICs provided rudimentary
computational and decision-making circuits
for control of mechanical device
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Topic 3: Evolution of Mechatronics

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Topic 3: Evolution of Mechatronics

Information Revolution
▪ Development of VLSI technology led to
the introduction of microprocessor,
microcomputer, and microcontroller.
▪ Now computing hardware is ubiquitous,
cheap, and small.
▪ As computing hardware can be
effortlessly interfaced with real world
electromechanical systems, it is now
routinely embedded in engineered
products/processes for decision-making.
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Topic 3: Evolution of Mechatronics

Information Revolution
▪ Microcontrollers are replacing precision
mechanical components, e.g., precision
machined camshaft that in many applications
functions as a timing device.
▪ Programmability of microcontrollers is
providing a versatile and flexible alternative to
the hard-wired analog/digital computational
hardware.
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Topic 3: Evolution of Mechatronics

Information Revolution
▪ Integrated computer-electrical-mechanical
devices are now capable of converting,
transmitting, and processing both the physical
energy and the virtual energy (information).
▪ Result: Highly efficient products and
processes are now being developed by
judicious selection and integration of sensors,
actuators, signal conditioning, power electronics,
decision and control algorithms, and computer
hardware and software.
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Topic 4: Elements of Mechatronics

▪ Mechanical elements refer to: mechanical

structure, mechanism, thermo-fluid, and
hydraulic aspects of a mechatronics system.
▪ Mechanical elements may include static/dynamic
characteristics.
▪ A mechanical element interacts with its
environment purposefully.
▪ Mechanical elements require physical power to
produce motion, force, heat, etc.
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Topic 4: Elements of Mechatronics

▪ Machine components – basic element

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Topic 4: Elements of Mechatronics

Electromechanical elements refer to:

A. Sensors
▪ A variety of physical variables can be
measured using sensors, e.g., light using
photo-resistor, level and displacement using
potentiometer, direction/tilt using magnetic
sensor, sound using microphone, stress and
pressure using strain gauge, touch using
micro-switch, temperature using thermistor,
and humidity using conductivity sensor.
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Topic 4: Elements of Mechatronics

B. Actuators
▪ DC servomotor, stepper motor, relay, solenoid,
speaker, light emitting diode (LED), shape
memory alloy, electromagnet, and pump apply
commanded action on the physical process
▪ IC-based sensors and actuators
• MEMS - In the most general form, it consist
of mechanical microstructures, microsensors,
micro-actuators and microelectronics, all
integrated onto the same silicon chip.
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Topic 4: Elements of Mechatronics

Control interface/computing hardware elements

▪ refer to Analog-to-digital (A2D) converter,
digital-to-analog (D2A) converter, digital
input/output (I/O), counters, timers,
microprocessor, microcontroller, data acquisition
and control (DAC) board, and digital signal
processing (DSP) board
▪ Control interface hardware allows analog/digital
interfacing communication of sensor signal to the
control computer and communication of control
signal from the control computer to the actuator.
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Topic 4: Elements of Mechatronics

Computer elements
▪ refer to hardware/software utilized to perform:
▪ computer-aided dynamic system analysis,
optimization, design and simulation
▪ virtual instrumentation
▪ rapid control prototyping
▪ hardware-in-the-loop simulation
▪ PC-based data acquisition and control
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Topic 4: Elements of Mechatronics

Typical knowledge base for optimal design and

operation of mechatronic systems comprises of:
▪ Dynamic system modeling and analysis
▪ Thermo-fluid, structural, hydraulic, electrical, chemical,
biological, etc.
▪ Decision and control theory
▪ Sensors and signal conditioning
▪ Actuators and power electronics
▪ Data acquisition
▪ A2D, D2A, digital I/O, counters, timers, etc.
▪ Hardware interfacing
▪ Rapid control prototyping
▪ Embedded computing
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Topic 4: Elements of Mechatronics

Typical knowledge base for optimal design and

operation of mechatronic systems comprises of:
▪ Dynamic system modeling and analysis
▪ Thermo-fluid, structural, hydraulic, electrical, chemical,
biological, etc.
▪ Decision and control theory
▪ Sensors and signal conditioning
▪ Actuators and power electronics
▪ Data acquisition
▪ A2D, D2A, digital I/O, counters, timers, etc.
▪ Hardware interfacing
▪ Rapid control prototyping
▪ Embedded computing
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Topic 4: Elements of Mechatronics

Key Elements of Mechatronics

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Topic 5: Mechatronics Application

▪ Smart consumer products: home security,

camera, microwave oven, toaster, dish
washer, laundry washer-dryer, climate
control units, etc.
▪ Medical: implant-devices, assisted surgery,
haptic, etc.
▪ Defense: unmanned air, ground, and
underwater vehicles, smart munitions, jet
engines, etc.
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Topic 5: Mechatronics Application

▪ Manufacturing: robotics, machines,

processes, etc.
▪ Automotive: climate control, antilock brake,
active suspension, cruise control, air bags,
engine management, safety, etc.
▪ Network-centric, distributed systems:
distributed robotics, tele-robotics, intelligent
highways, etc.
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Topic 5: Mechatronics Application

▪ Manufacturing: robotics, machines,

processes, etc.
▪ Automotive: climate control, antilock brake,
active suspension, cruise control, air bags,
engine management, safety, etc.
▪ Network-centric, distributed systems:
distributed robotics, tele-robotics, intelligent
highways, etc.
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Topic 6: Relay Logic Diagram

▪ Relay logic diagrams are sometimes called elementary

diagrams, line diagrams, or relay ladder logic (RLL)
▪ Relay logic diagrams are very important because they
show the symbols for different input and output
devices. The first step in creating a program for a PLC is
creating the relay logic diagram. After the relay logic
diagram is drawn, it is then converted to a PLC ladder
logic diagram, often called a ladder diagram. The
ladder diagram is used to program the programmable
logic controller (PLC). The program defines the
operations to be performed by the PLC.
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Topic 6: Relay Logic Diagram

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Topic 6: Relay Logic Diagram

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Topic 6: Relay Logic Diagram

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Topic 6: Relay Logic Diagram

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Topic 6: Relay Logic Diagram

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Topic 6: Relay Logic Diagram

Ladder Diagram Common Characteristics

▪ Power bar on the far left
▪ Current flow from the switches combined to
allow flow
▪ One or more relay coils at the right
▪ Neutral or negative power bar on the right
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Topic 6: Relay Logic Diagram

Ladder Diagram Common Characteristics

▪ Power bar on the far left
▪ Current flow from the switches combined to
allow flow
▪ One or more relay coils at the right
▪ Neutral or negative power bar on the right
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Topic 6: Relay Logic Diagram

Boolean Logic
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Topic 6: Relay Logic Diagram

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Design
In order to develop control circuitry for multi cylinder
applications, it is necessary to draw the motion
diagram to understand the sequence of actuation of
various signal input switches-limit switches and sensors.
Motion diagram represents status of cylinder position -
whether extended or retracted in a particular step
▪ Example: In a press shop, stamping operation to be
performed using a stamping machine. Before stamping,
work piece has to be clamped under stamping
station. Then stamping tool comes and performs
stamping operation. Work piece must be unclamped
only after stamping operation.
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Design
Step 1: Write the statement of the problem:
Let A be the clamping cylinder and B be the
stamping cylinder as shown in the Figure.
First cylinder A extends and brings under
stamping station where cylinder B is located.
Cylinder B then extends and stamps the job.
Cylinder A can return back only cylinder B has
retracted fully.
Step 2: Draw the positional layout.
Step3: Represent the control task using
notational form.
Therefore, given sequence for clamping and
stamping is A+B+B-A-
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Design
Step 4 Draw the Displacement –step diagram
Step 5 Draw the Displacement –time diagram
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Design
Step 6: Analyze and Draw Pneumatic circuit.
Step 6.1 Analyze input and output signals.
▪ Input Signals
Cylinder A – Limit switch at home position ao
Limit switch at home position a1
Cylinder B - Limit switch at home position bo
Limit switch at home position b1
▪ Output Signal
Forward motion of cylinder A ( A+)
Return motion of cylinder A (A-)
Forward motion of cylinder B( B+)
Return motion of cylinder B( B+)
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Design
Step 6: Analyze and Draw Pneumatic circuit.
Step 6.1 Analyze input and output signals.
▪ Input Signals
Cylinder A – Limit switch at home position ao
Limit switch at home position a1
Cylinder B - Limit switch at home position bo
Limit switch at home position b1
▪ Output Signal
Forward motion of cylinder A ( A+)
Return motion of cylinder A (A-)
Forward motion of cylinder B( B+)
Return motion of cylinder B( B+)
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Design
Step 6: Analyze and Draw Pneumatic circuit.
Step 6.2 Using the displacement time/step diagram
link input signal and output signal.
Usually start signal is also required along with
a0 signal for obtaining A+ motion.
1. A+ action generates sensor signal a1, which is used
for B+ motion
2. B+ action generates sensor signal b1, which is
used for B- motion
3. B- action generates sensor signal b0, which is used
for A- motion
4. A- action generates sensor signal a0, which is used
for A+ motion
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Design

Pneumatic Fittings
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Design

Pneumatic Tube
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Design Double Coil

Solenoid Valve

Manifold

Single Coil Double Coil

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Design

Pneumatic Cylinder
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Design

Limit Switch
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Design

Proximity Switch
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Design

Rules for Drawing Relay Logic

Diagrams
Rule 1. Input devices are placed near the left corner of the
rung. This means that switches, pushbuttons, and contacts
are placed near the left corner of each rung. Figure 5-5
displays a correct relay logic diagram in which two
switches, one pushbutton, and one motor are placed in the
first rung. In this example, we must close switch one
(SW1) and two (SW2) and press the normally open
pushbutton (PB1) to turn the motor on.
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Design

Rules for Drawing Relay Logic

Diagrams
Rule 1. Input devices are placed near the left corner of the
rung. This means that switches, pushbuttons, and contacts
are placed near the left corner of each rung. Figure 5-5
displays a correct relay logic diagram in which two
switches, one pushbutton, and one motor are placed in the
first rung. In this example, we must close switch one
(SW1) and two (SW2) and press the normally open
pushbutton (PB1) to turn the motor on.
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Design
Rule 2. One (and only one) output is placed near the right
corner of the rung. This means that one output device such
as a motor, a pilot light, or a relay coil must be placed near
the right corner of the rung. In the figure displays a correct
relay logic diagram in which the motor is placed near the
right corner of the first rung. Figure 5-6 displays an
incorrect relay logic diagram in which the output is in the
middle of the rung.
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Design
Rule 3. Input devices can be connected in series, parallel,
or a combination of series and parallel. In the figure
displays five input devices connected in a combination of
series and parallel. In this example, when switch one
(SW1), switch two (SW2), and pushbutton one (PB1) are
closed, the motor turns on. Also, when switch one (SW1),
switch three (SW3), and limit switch one (LS1) are closed,
the motor turns on. Either or both combinations turn the
motor on.
Rule 4. Output devices cannot be connected in series.
Only parallel output devices can be placed in a rung.
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Design
Rule 5. While input devices can be represented multiple
times in the relay logic diagram, each output device can
only be represented once in the diagram.
Rule 6. All the input and output devices must be placed
horizon-tally. This means that no vertically positioned input
or output devices are allowed in a relay logic diagram.
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Design
Rule 9. The location of each contact associated with a coil
can be recorded by the right-hand rail near the coil. In the
Figure, the normally closed contact in rung 2 and the
normally open contacts in rungs 1 and 3 are associated
with M1.
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Design
Rule 7. Current in the relay logic diagram must flow from
left to right.
Rule 8. Diagrams must be numbered and commented
correctly. Rung numbers are placed on the left side of each
rung. The instruction symbols and comments are placed
above the instruction. Rung comments are placed on the
right side of each rung.
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Activity

▪ Design a circuit that will light

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References
Books

Online Sources
• http://www.tesla-institute.com/index.php/mechatronic-art
icles/95-mechatronics-design-process-system
• https://www.thomasnet.com/articles/pumps-valves-acce
ssories/all-about-float-valves/
• https://www.scribd.com/document/
360446305/9781605250069-ch05-pdf
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