Objectives

1. Understand key elements of Mechatronics system,

representation into block diagram
2. Understand concept of transfer function, reduction and
analysis
3. Understand principles of sensors, its characteristics,
interfacing with DAQ microcontroller
4. Understand the concept of PLC system and its ladder
programming, and significance of PLC systems in industrial
application
5. Understand the system modeling and analysis in time domain
and frequency domain.
6. Understand control actions such as Proportional, derivative
and integral and study its significance in industrial
applications.
 Outcomes

1. Identification of key elements of mechatronics

system and its representation in terms of block
diagram
2. Understanding the concept of signal processing and use
of interfacing systems such as ADC, DAC, digital I/O
3. Interfacing of Sensors, Actuators using appropriate DAQ
micro-controller
4. Time and Frequency domain analysis of system model (for
control application)
5. PID control implementation on real time systems
6. Development of PLC ladder programming and
implementation of real life system
Syllabus
Unit –I. Introduction to Sensors & Actuators
• Introduction to Mechatronics,
Measurement characteristics: - Static and Dynamic
• Sensors:
Position Sensors: - Potentiometer, LVDT, Encoders;
Proximity sensors:- Optical, Inductive , Capacitive;
Motion Sensors:- Variable Reluctance;
Temperature Sensor: RTD, Thermocouples;
Force / Pressure Sensors:- Strain gauges;
Flow sensors: - Electromagnetic

• Actuators: Stepper motor, Servo motor, Solenoids

• Selection of sensors
What is Mechatronics?
✓ Mechatronics is the synergistic combination of Mechanical
engieering (“mecha”for mechanisms), Electronic engineering
(“tronics” for electronics), and
software engineering.

✓ The word “Mechatronics” was first coined by Mr. Tetsuro Moria,

a senior engineer of a Japanese company, Yaskawa, in 1969.

Cont………..
 Cont………..
✓It is a multi-disciplinary
approach to product and
manufacturing system design.

✓It involves application of

electrical, mechanical, control
and computer engineering to
develop products, processes and
systems with greater
flexibility, ease in redesign and
ability of reprogramming.

✓It concurrently includes all

these disciplines.
 Mechatronics system
• A Mechatronics system
integrates various
technologies involving
1.Sensors & Measurement
systems,
2.Drives & Actuation systems
(Mechanical /Pneumatics
/Hydraulics),
3.Controlling system
(microprocessor /
microcontroller /PLC) and
software engineering.
Introduction-
✓Mechatronics can also be termed as replacement of mechanics
with electronics or enhance mechanics with electronics.

✓With the help of microelectronics and sensor technology,

mechatronics systems are providing high levels of precision and
reliability.

For example, in modern automobiles, mechanical fuel injection

systems are now replaced with electronic fuel injection systems.
This replacement made the automobiles more efficient and less
pollutant.

✓By employment of reprogrammable microcontrollers or PLC, it is

now easy to add new functions and capabilities to a product or a
system.

✓Today’s domestic washing machines are “intelligent” and four-wheel

passenger automobiles are equipped with safety installations such as
air-bags, parking (proximity) sensors, antitheft electronic keys etc.
 Power
Physical Signal
Mecha
nism Physical Signal

Mechanical
Power Actua Senso
tor r
Electronic

Electronic signal Electronic Electronic signal

Device
 LOW EASY TO
POWER, USE AND
CONTROL ACCURACY,
FAST, COMPLEX
MULTIPLE JOBS
TASK

WHY
MECHATR
ONICS
Objective of Mechatronics system

1. Integration of mechanical systems

with electronic and computer systems.
1. To improve efficiency of the system.
2. To reduce cost of production.
3. To achieve high accuracy and precision.
4. For easy control of the system.
5. Customer satisfaction and comfort.
Mechatronics has evolved through the following stages:
1.Primary Level Mechatronics: Integrates electrical signaling with
mechanical action at the basic control level for e.g. fluid valves and relay
switches

2.Secondary Level Mechatronics: Integrates microelectronics into electrically

controlled devices for e.g. cassette tape player.

3.Tertiary Level Mechantronics: Incorporates advanced control strategy

using microelectronics, microprocessors and other application specific
integrated circuits for e.g. microprocessor based electrical motor used for
actuation purpose in robots.

4.Quaternary Level Mechatronics: This level attempts to improve smartness

a step ahead by introducing intelligence ( artificial neutral network and fuzzy
logic ) and fault detection and isolation ( F.D.I.) capability into the system.
eg: artificial neural network and fuzzy logic technologies.
The function of Mechatronics engineer is:
Design and prepare the machines and Programming
them , by using the computer, control systems,
electrical and mechanical system .
Elements of Mechatronics
Modeling
Analysis
Integrated
Design
testing
Mechatronics system
Example
Mechatronics Applications-
✓ Smart consumer products: home security, camera,
microwave oven, toaster, dish washer, laundry washer-
dryer, climate control units, etc.
✓ Medical: implant-devices, assisted surgery, etc.
✓ Defense: unmanned air, ground, and underwater
vehicles, smart munitions, jet engines, etc.
✓ 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.
Applications of Mechatronics Systems

Cars

Tools Computers
Stealth
Bomber

High Speed Trains

Consumer
Electronics
MEMS
 Mechatronics Systems in Manufacturing
Applications
Micro Factory Micro Factory
Drilling Unit
•Desktop sized Factory
•Build small parts with a small
factory
•Greatly reduces space, energy, and
materials
Mechatronics Systems in Manufacturing Applications

CNC Bending
•Fully automated bending: load sheet metal and the finished
bent parts come out
•Can bend complex shapes
Mechatronics Systems in Transportation
Applications

Typical Applications
•Brake-By-Wire system
•Steer-By-Wire
•Integrated vehicle dynamics
•Camless engines
•Integrated starter alternator

Automobiles
✓Reliability
✓Reduced weight
✓Fuel economy
✓Manufacturing flexibility
✓Design freedom
✓Advanced safety features
✓Cost
Transportation Applications

High Speed Trains

✓Train Position and Velocity

constantly monitored from
main command center.
✓Error margin in scheduling
no more than 30 seconds
✓Fastest trains use magnetic
levitation
JR-Maglev
Top Speed: 574 km/h (357 mph)
Country: Japan
Magnetic Levitation

Transrapid
Top Speed: 550 km/h (340 mph)
Country: German
 Transportation Applications
Segway

Systems Uses
✓Tilt and pressure sensors
✓Microcontroller
✓Motors
✓Onboard power source
Advantages
Simple and intuitive personal transportation
device
Smart Robotics Application
Big Dog

System Can
•Carry 340 lb Advantages
•Run 4 mph Robot with rough-terrain mobility that could
•Climb, run, and walk carry equipment to remote location.
•Move over rough terrain
Smart Robotics Application
Robots can vacuum floors and clean gutters so you don't have to.

Cleans Gutter Vacuum Floors

Medical Applications
Prosthetics
Arms, Legs, and other body parts can be
replaced with electromechanical ones.
Medical Applications
Pace Maker
Used by patients with slow or erratic heart
rates. The pacemaker will set a normal heart
rate when it sees an irregular heart rhythm.

Implantable Defibrillation

Monitors the heart. If heart

fibrillates or stops completely it
will shock the heart at high voltage
to restore a normal heart rhythm.
Defense Applications
•Advanced technology is making our soldiers safer.
•Some planes can now be flown remotely.

Unmanned Aerial Vehicle Stealth Bomber

Sanitation Applications
System Uses
✓Proximity sensors
✓Control circuitry
✓Electromechanical valves
✓Independent power source

Advantages
•Reduces spread of germs by making device
hands free
•Reduces wasted water by automatically turning
off when not in use
Sanitation Applications
Systems Uses Paper Towel Dispenser
✓Motion sensors
✓Control circuitry
✓Electromechanical actuators
✓Independent power source

Soap Dispenser

Advantages
•Reduces spread of germs by making device hands free
•Reduces wasted materials by controlling how much is
dispensed
Smart Home Applications
Smoke Detector System
Why Mechatronics ?
Advantages
1.High level of integration.
2.Increased functionality and better design.
3.More use of electronics and software.
4.Use of artificial intelligence and intelligent process control
5.Assume responsibility for a process and operation with little
interference of operators.
6.Multisensory and programs environments.
7.High reliability and safety.
8.The products produced are cost effective and very good quality.
9. High degree of flexibility
10. Greater extent of machine utilization
11. Greater productivity
12. High life expected by proper maintenance.
13. The integration of sensor and control system in a complex
system reduces capital expenses
Disadvantages of Mechatronics System
1.The initial cost is very high.

2.The complicated design and system.

3.The repair and maintenance in complex.

4.Its replacement is difficult, that it is difficult to change old

system to new system.
5. Imperative to have Knowledge of different engineering fields
for design and implementation.
6.Specific problem of various systems will have to be
addressed separately and properly
CAREER PATHS – MECHATRONICS Engg
Automobile Medic Material
al Processing

Aerospac Manufacturin
e g

Roboti
cs