INTRODUCTIO
N
ELEMENTS OF MECHATRONICS
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Topic
SL.NO TOPIC s
1 Introduction to Mechatronics
systems, Concepts & Application.
2 Mechatronics System Components
with examples
3 Measurement Systems, Control
systems, Open & Closed Loop
Systems.
4 Sequential Controllers with examples
– Water level controller.
5 Shaft speed control, Washing machine
control.
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6 Automatic camera and
Engine management
Introduction to Mechatronics
Systems
The word mechatronics was originated from Japan (Yasakawa Electric Company) in the
late 1960s, spread through Europe, and is now commonly used round the globe.
“The word, mechatronics, is composed of ‘mecha’ from mechanism and the ‘tronics’
from electronics.
Mechatronics solves technological problems using interdisciplinary knowledge consisting
of mechanical engineering, electronics, and computer technology.
In 1996, Harashima, Tomizuka, and Fukuda defined mechatronics as being “the
synergistic integration of mechanical engineering, with electronics and intelligent
computer control in the design and manufacturing of industrial products and processes.”
Bolton presented yet another definition by saying “a mechatronic system is not just a
marriage of electrical and mechanical systems and is more than just a control system; the
mechatronic system is a complete integration of them all.”
Mechatronics is the field of study concerned with the design, selection, analysis, and
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control of systems that combine mechanical elements with electronic components,
Working definition
Mechatronics is the synergistic integration of sensors, actuators, signal conditioning,
power electronics, decision and control algorithms, and computer hardware and software
to manage complexity, uncertainty, and communication in engineered systems.
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Graphical Representation of
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Evolution of
Mechatronics
Technological advances in design, manufacturing, and of engineered
operation products/devices/processes can be traced through:
– Industrial revolution
– Semiconductor revolution
– Information revolution
Industrial Revolution
• Allowed design of products and processes for energy conversion and transmission thus
allowing the use of energy to do useful work.
• Engineering designs of this era were largely mechanical
– e.g., operations of motion transmission, sensing, actuation, and computation were
performed using mechanical components such as cams, gears, levers, and linkages).
• Purely mechanical systems suffer from
– Power amplification inability.
– Energy losses due to tolerances, inertia, and friction.
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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 devices.
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Information
• Development of VLSI technology led to
Revolution introduction of microprocessor,
microcomputer,
the and microcontroller.
• Now computing hardware is every where, 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.
–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.
–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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Mechatronics has evolved through the following
stages:
•Primary Level Mechatronics: Integrates electrical signaling with mechanical action at the
basic control level for e.g.fluid valves and relay switches
•Secondary Level Mechatronics: Integrates microelectronics into electrically controlled
devices for e.g. cassette tape player.
•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.
•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.
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Mechatronics
•Smart consumer products: home security, camera, microwave oven, toaster, dish washer,
Applications
laundry washer-dryer, climate control units, Automatic Digital Cemera etc.
•Computer disk VCR/DVD drives, ATM, etc
• Medical: implant-devices, assisted surgery, haptic, etc.
• Defense: unmanned air, ground, and underwater vehicles, smart weapons, jet engines,
etc.
• Manufacturing: NC & CNC machine tools, Rapid Prototyping, robotics, etc.
•Automotive: climate control, antilock brake, active suspension, cruise control, air bags,
engine management, safety, etc.
•Network-centric, distributed systems: distributed robotics, telerobotics, intelligent highways,
etc.
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Advantages of
Mechatronics
Cost effective and good quality products
High degree of flexibility to modify or redesign
Very good performance characteristics
Wide area of application
Greater productivity in case of manufacturing organization
Greater extend of machine utilization
Disadvantages of Mechatronics
High Initial cost
Multi-disciplinary engineering background required to design and implementation
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Need of highly trained workers
Key elements of Mechatronics
systems
Key elements of Mechatronics systems can be classified under
following categories
1. Information systems
2. Mechanical systems
3. Electrical systems
4. Computer system
5. Sensors and actuators
6. Real time interfacing
Elements of Mechatronics
System
Actuators & Sensors
Signals & Conditioning
Digital Logic System
Software & Data
acquisition
Systems
Computers &
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Display
devices
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Actuators &
Sensors
Sensors and actuators come under mechanical
systems
Actuators Sensors
The actuators The sensors detect the state
produce motion or cause of the system parameters,
some action inputs and outputs
Various actuators: Pneumatic Various Sensors: Liner and
an hydraulic actuators, rotaional
Electro Mechanical actuators, sensors, acceleration
Piezoelectric, sensors, force, torque,
Electrical Motors, i.e. D.C, pressure sensor,
A.C, Stepper, Servo motors. temperature, proximity and
light sensors.
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Signals &
Conditioning
Mechatronic system deals with two types of signals and conditioning , i.e.
Input & Output
Input devices receive input signals from the mechatronics
system via interfacing devices an sensors.
From sensors the signal is send to the control circuits for conditioning or
processing.
Various input signal conditioning devices are amplifiers, A2D, D2D converters .
Output signals from the system are send to the output/display devices through
interfacing devices
Various output signal conditioning devices are D2A, display decoders, power
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transistors, op-amps.
Digital
Thermometer
The thermocouple is a transducer that converts temperature to a small voltage; the
amplifier increases the magnitude of the voltage; the A/D (analog-to-digital)
converter is a device that changes the analog signal to a coded digital signal; and
the LEDs (light emitting diodes) display the value of the temperature.
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Digital Logic
System
It will control overall system operation
Various digital logic systems are logic circuits, microcontrollers, PLC, sequencing
& timing controls
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Software & Data acquisition
Systems
Data acquisition system acquires the output signals from sensors in the form of
voltage, frequency, resistance etc. an inputting into the microprocessor or
computer.
Software is used to control the acquisition of data through DAC board.
Data acquisition system consists of multiplexer, amplifier, register and control
circuits.
Software Examples: Ladder Logic, Visual C++, Visual Basic, Lab VIEW, MATLAB,
Lab Chart, LOX
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Using Lab
VIEW
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Computers and display
Computers are usedevices
to store large amount of data and process further
through software.
Display devices are used to give visual feedback to the
user. Display devices are LED, CRT,LCD, Digital displays
etc.
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Measurement
System
What is a
system?
Input, Output
Electrical ,
Power MOTO Rotaio
R n
Not concentrate on what goes on inside
Concentrate only on output & Input device
Measurement
system? Output
Measurin Input quantity Measureme the value
g nt System of quantity
Output
Input Temp. Thermometer number on
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scale
Digital
Thermometer
The thermocouple is a transducer that converts temperature to a small voltage; the
amplifier increases the magnitude of the voltage; the A/D (analog-to-digital)
converter is a device that changes the analog signal to a coded digital signal; and
the LEDs (light emitting diodes) display the value of the temperature.
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Control
System
To control the output to some particular value or particular sequence of
values
Input, required Central Heating Output, temperature at the
temperature system set value
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Difference between Open loop and Closed loop
system
SI.No. Open loop system Closed loop system
1 Not using feedback Feedback using
2 Less accurate More accurate
3 Simple in construction Complicated in construction
4 Optimisation in control is not possible Optimisation in control is possible
5 Easy maintenance & cost is less Difficult to maintain & cost is more
6 Eg. CD deck, Digital thermometer Eg. Automatic water level, washing
machine
Open Loop
system
Example of open loop system
Closed loop
system
Basic Elements of a closed loop
system
1. Comparison element
2. Control element
3. Correction element
4. Process elements
5. Measurement elements
Example of Closed loop system
Various elements for controlling the
room temperature.
Controlled variable - the room temperature
Reference value - the required room temperature
Comparison element - the person comparing the measured value wit required temp.
Error signal - difference between measured and required temperatures
Control unit - the person
Correction unit - the switch on the fire
Process unit - the heating by the fire
Measuring device - a thermometer
Shaft Speed
Control
Water Level
Controller
Washing machine Control
Various Events of Washing M/C
Washing machine control
Cam operated
Switch
Engine Management
system
Automatic
Camera
The Digital
Camera
