Dr. S.H.

Upadhyay
Mechanical & Industrial Engineering Deptt.
IIT Roorkee
CWS-25; MTE-25; ETE-50
1.Introduction to mechatronics and mechatronics
approach; measurement system; control systems;
microprocessor based controllers.
2.Sensors and transducers:Performance terminology;
photoelectric transducers; flow transducers; optical
sensors and transducers; semiconductor lasers,
selection of sensors, mechanical/electrical
switches, inputting data by switches.
3.Actuators and mechanisms: Actuation systems;
pneumatic and hydraulic systems; process control
valves; rotary actuators; mechanical actuation
systems; electrical actuation systems
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4. Signal conditioning: Signal conditioning; filtering
digital signals; Multiplexers; Data acquisition;
Digital signal processing; Pulse modulation; data
Presentation systems.
5. Microprocessors and microcontrollers: Control;
microcomputer structure; Microcontrollers;
applications; programmable logic controllers.
6. Modeling & system response: Mathematical
models; Mechanical, electrical, hydraulic and
thermal Systems; Dynamic response of systems;
Transfer function and frequency response; closed
loop controllers; MATLAB as development tool.
7. Design and Mechatronics: Input/output system;
Computer based modular design; System
validation; Remote monitoring and control;
Designing; Possible design solutions; Case studies.
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Mechatronics: Bolton, W., Longman
Introduction to Mechatronics: D.G.
Alciatore & Michael B. Histand; Tata
Mc Graw Hill
Mechatronic system Design; Shetty
Dedas, Kolk and Richard
Mechatronic handbook: Bishop; CRC
press
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The name [mechatronics] was coined by Ko Kikuchi, now
president of Yasakawa Electric Co., Chiyoda-Ku, Tokyo.
The word, mechatronics is composed of mecha from mechanics
and tronics from electronics. In other words, technologies and
developed products will be incorporating electronics more and
more into mechanisms, intimately and organically, and making it
impossible to tell where one ends and the other begins.
Mechatronics
mecha
tronics Eletronics
Mechanics
Harashima, Tomizuka, and Fukada, 1996
Synergistic integration of mechanical engineering with
electronics and intelligent computer control in the design and
manufacturing of industrial products and processes.
Auslander and Kempf, 1996
Mechatronics is the application of complex decision making
to the operation of physical systems.
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Shetty and Kolk in 1997
Mechatronics is a methodology used for the optimal design
of electromechanical products.
W. Bolton, 1995
Integration of electronics, control engineering, and
mechanical engineering.
S. Ashley, 1997
Synergistic use of precision engineering, control theory,
computer science, and sensor and actuator technology to
design improved products and processes.
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D. G. Alciatore and M. B. Histand,1998
Field of study involving the analysis, design, synthesis, and
selection of systems that combine electronics and mechanical
components with modern controls and microprocessors.
Mechatronics is generally
recognized worldwide as a vibrant area of study.
Undergraduate and graduate programs in mechatronic
engineering are now offered in many universities.
Refereed journals are being published and dedicated
conferences are being organized and are generally highly
attended.
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Implementing electronics control in a
mechanical system.
Enhancing existing mechanical design with
intelligent control.
Replacing mechanical component with a
electronic solution.
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Mechanical Engineering
Electrical Engineering
Computer Engineering
Computer/Information Systems
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Information
Systems
Electrical
Systems
Computer
Systems
Mechanical
Systems
Mechatrnoics
The need
Analysis of problem
Preparation of Specification
Generation of possible solutions
Selection of a suitable solution
Production of a detailed design
Production of working drawings
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TRADITIONAL DESIGN: The temperature control for a
domestic central heating system has been the bi-metallic
thermostat of a closed loop control system. The bending of
bi-metallic strip changes as the temperature changes and is
used to operate an on/off switch for the heating system.
The bi-metallic thermostat is comparatively crude and
the temperature is not accurately controlled; also
devising a method for having different temperatures at
different times of the day is complex and not easily
achieved.
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MECHATRONIC DESIGN: A mechatronic solution to the
problem might be to use a microprocessor controlled
system employing perhaps a thermo-diode as the sensor
The microprocessor-controlled system can, however,
cope easily with giving precision and programmed
control. The system is much more flexible. This
improvement in flexibility is a common characteristic
of mechotronics systems when compared with
traditional systems.
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Real life applications:
THERMOSTAT
TRADITIONAL DESIGN
MECHATRONICS DESIGN
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TRADITIONAL THERMOSTAT DESIGN TRADITIONAL THERMOSTAT DESIGN
SECTIONAL VIEW COMPONENTS OF THERMOSTAT
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CONVERSION TO MECHATRONIC DESIGN CONVERSION TO MECHATRONIC DESIGN
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A PICK A PICK--AND AND--PLACE ROBOT PLACE ROBOT
The basic form of a Pick-and-Place robot unit is
shown in the Figure (a).
The robot has three axes, about which the motion
can occur i.e. rotation in a clockwise or counter
clockwise direction of the unit on its base, arm
extension or contraction and arm up and down; also
the gripper can open and close.
These movements can be actuated by the use of
pneumatic cylinders operated by solenoid-controlled
valves with limit switches to indicate when a motion
is completed.
Thus the clockwise rotation of the unit might result
from the piston in a linear cylinder being extended
and the counter clockwise direction by its retraction.
Likewise the upward movement of the arm might
result from the piston in a linear cylinder being
extended and the downward motion from it
retracting; the extension of the arm by the piston in
another cylinder extending and its return movement
by the piston retracting.
The gripper can be opened or closed by the piston in
a linear cylinder extending or retracting. Figure (b)
shows a basic mechanism that could be used
Figure (a)
Figure (b)
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MECHATRONICS SOLUTION MECHATRONICS SOLUTION
Figure below shows how a micro controller could be used to
control the solenoid valves and hence the movements of the
robot unit.
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CAR PARK BARRIERS CAR PARK BARRIERS
As an illustration of a PLC, consider the
coin-operated barriers for a car park.
The in-barrier is to open when the
correct money is inserted in the
collection box and the out-barrier is to
open when a car is detected at the car
park side of the barrier.
The Figure shows the types of valve
systems that can be used to lift and
lower the pivoted barriers.
When a current flows through the
solenoid of valve A, the piston in a
cylinder moves upwards and causes the
barrier to rotate about its pivot and raise
to a let a car through. When the current
through solenoid of valve A ceases, the
return spring of the valve results in the
valve position changing back to its
original position.
When the current is switched to through
the solenoid of valve B the pressure is
applied to lower the barrier. Limit
switches are used to detect when the
barrier is down and also when fully up.
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MECHATRONICS SOLUTION MECHATRONICS SOLUTION
PLC connections Ladder diagram
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ADVANTAGES OF MECHATRONICS DESIGN ADVANTAGES OF MECHATRONICS DESIGN
HIGH RESOLUTION & ACCURACY
REDUCES HOUSE HOLD HEATING COST
SELF CALIBRATING
FLEXIBLE DESIGN
ENVIRONMENTAL FRIENDLY
In the late 1970s, the Japan Society for the Promotion of
Machine Industry (JSPMI) classified mechatronic products
into
Class I:
Primarily mechanical products with electronics
incorporated to enhance functionality.
Examples include numerically controlled machine tools and
variable speed drives in manufacturing machines.
Class II:
Traditional mechanical systems with significantly updated
internal devices incorporating electronics. The external user
interfaces are unaltered.
Examples include the modern sewing machine and
automated manufacturing systems.
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Class III:
Systems that retain the functionality of the traditional
mechanical system, but the internal mechanisms are
replaced by electronics.
An example is the digital watch.
Class IV:
Products designed with mechanical and electronic
technologies through synergistic integration.
Examples include photocopiers, intelligent washers and
dryers, and automatic ovens.
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The enable technologies for each mechatronic product class
illustrate the progression of electromechanical products in
stride with developments in control theory, computation
technologies, and microprocessors.
Class Class II products products were enabled by servo technology, power
electronics, and control theory.
Class Class II II products products were enabled by the availability of early
computational and memory devices and custom circuit design
capabilities.
Class Class III III products products relied heavily on the microprocessor and
integrated circuits to replace mechanical systems.
Class Class IV IV products products marked the beginning of true mechatronic
systems, through integration of mechanical systems and
electronics.
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It was not until the 1970s with the development of the
microprocessor by the Intel Corporation that
integration of computational systems with mechanical
systems became practical.
The electronic ignition system was one of the first
mechatronic systems to be introduced in the
automobile in the late 1970s.
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In several technical areas the integration of products or
processes and electronics can be observed.
This is especially true for mechanical systems which
developed since about 1980.
These systems changed from electro-mechanical systems with
discrete electrical and mechanical parts to integrated
electronic-mechanical systems with sensors, actuators, and
digital microelectronics.
These integrated systems, as seen in Table are called
mechatronic systems , with the connection of MECHAnics and
elecTRONICS.
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All these definitions agree that mechatronics is an
interdisciplinary field , in which the following
disciplines act together (see Figure)
mechanical systems (mechanical elements, machines,
precision mechanics);
electronic systems (microelectronics, power
electronics, sensor and actuator technology); and
information technology (systems theory, automation,
software engineering, artificial intelligence).
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Mechatronics: synergetic integration of different disciplines.
Some modern mechanical process like a power
producing or a power generating machine. A primary
energy flows into the machine and is then either directly
used for the energy consumer in the case of an energy
transformer, or converted into another energy form in
the case of an energy converter.
The form of energy can be electrical, mechanical
(potential or kinetic, hydraulic, pneumatic), chemical,
or thermal. Machines are mostly characterized by a
continuous or periodic (repetitive) energy flow.
For other mechanical processes, such as mechanical
elements or precision mechanical devices, piecewise or
intermittent energy flows are typical.
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Mechanical process and information
processing develop towards mechatronic
systems.
Division of Functions between Mechanics and
Electronics
Improvement of Operating Properties
Addition of New Functions
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General scheme of a (classical) mechanical-electronic system.
More features
Higher precession
User friendly
More flexible
Lower cost, Efficient
Environment friendly.
Smaller geometry.
More reliable.
Safer
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Above figure illustrates all the components in
a typical mechatronic system.
The actuators produce motion or cause some
action.
The sensors detect the state of the system
parameters, input, and output; digital devices
control the system;
Conditioning and interfacing circuits provide
connections between the control circuits and
input/output devices and
Graphical display provide visual feedback to
users.
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System can be thought of as a box which has
an input and an output and where we are not
concerned with what goes on inside the box
but only the relationship between the output
and the input.
A fundamental part of many mechatronic system is a
measurement system composed of the three basic parts shown
in fig.
The transducer is a sensing device that converts a physical
input into an output, usually a voltage.
The signal processor performs filtering, amplification, or other
signal conditioning on the transducer output.
The term sensor is often used to refer to the transducer or to
the combination of transducer and signal processor.
Finally recorder is an instrument, a computer, a hard-copy
device or simply a display that maintains the sensor data for
online monitoring or subsequent processing.
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Signal processor Transducer
Recorder
Elements of a measurement system
A black box used for making measurements.
It has the input the quantity being measured
and output the value of the quantity.
Example: temperature measurement system
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Input
Temperature
Thermometer
Output
Number on
a scale
An example of a measurement system
The given figure is also another example of a
measurement system.
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;
The LED (light emitting diodes) display the
value of the temperature.
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signal conditioner display
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A control system can be thought of as a black box
which is used to control its output to some particular
value or particular sequence of value.
For example, a domestic central heating control
system has as its input the temperature required in
the house and as its output the house at the
temperature.
i.e set the required temperature on the thermostat or
controller and the heating furnace adjusts itself to
pump water through radiators and so produce the
required temperature in the house.
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Central Heating System
Input
Required
temperature
Output
Temper
ature of
the set
value
Open loop systems
Closed loop systems
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Switch Electric fire
Input
Decisi
on to
switch
on or
off
Electric
power
Output
Temper
ature
change
Open Loop System Open Loop System
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Input
Requir
ed
temper
ature
Switch Electric fire
Electric
power
Output
A
constant
tempera
ture
Measuring
device
-
+
Comparison element
Deviation
signal
Feedback of temperature signal
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Controlled
variable
Refer
ence
value
Control unit
Correction
unit
Measuring
device
-
+
Comparison element
Error
signal
Measured value
Process
Comparison element
This compares the required or reference value of
the variable condition being controlled with the
measured value of what is being achieved and
produces and error signal. It can be regarded as
adding the reference signal, which is positive, to
the measured value signal, which is negative in this
case:
Error signal= reference value signal measured value
signal
Control element
This decides what action to take when it receives an
error signal.
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Correction element
The correction element produces a change in the
process to correct or change the controlled
condition.
Thus it might be a switch which switches on a
heater and so increase the temperature of the
process or a valve which opens and allows more
liquid to enter the process.
Process element
The process is what is being controlled.
It could be a room in a house with temperature
being controlled or a tank of water with its level
being controlled.
Measurement element
The measurement element produces a signal
related to the variable condition of the process that
is being controlled.
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Controlled variable - the room temperature
Reference value - the required room temperature
Comparison element -the person comparing the
measured value with the required
value of the temperature
Error signal -the difference between the
measured and required
temperatures
Control unit -the person
Correction unit -the switch on the fire
Measuring device - a thermometer
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The digital integrated circuit (IC) called a
microprocessors [Figure].
This revolution has occurred because the
microprocessor brings the flexibility of
program control and the
computational power of a computer to bear
on any problem.
Microprocessors are now rapidly replacing
the mechanical cam-operated controllers
and being used in general to carry out
control functions.
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In many simple systems there might be just
an embedded microcontroller, this being a
microprocessor with memory all integrated
on one chip, which has been specifically
programmed for the task concerned.
microprocessor-based control systems are
rapidly replacing many older control systems
based on analog circuits or electromechanical
relays
One of the first microprocessor-base
controllers made specifically for control
applications was the programmable logic
controller (PLC).
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This is a microprocessor-based controller
which used programmable memory to store
instructions and to implement functions
such as logic, sequence, timing counting
and arithmetic to control events and can be
readily reprogrammed for different tasks.
A microprocessor by itself is not a computer;
additional components such as memory and
input/output circuits are required to make it
operational
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Outputs
Inputs
A
Controller
Control program
B
D
C
P
Q
R
S
Programmable logic controller
However, the microcontroller Figure, which is a
close relative of the microprocessor, does contain
all the computer functions on a single IC,
Microcontroller lack some of the power and speed
of the newer microprocessors, but their
compactness is ideal for many control applications;
most so-called microprocessor controlled devices,
such as vending machines, are really using
microcontrollers.
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Some specific reasons for using a digital, microprocessr
design in control systems are the following:
Low level signals from sensors once converted to
digital, can be transmitted long distances virtually
error-free.
A microprocessor can easily handle complex
calculations and control strategies.
Long term memory is available to keep track of
parameters in slow moving system.
Changing the control strategy is easy by loading in a
new program; no hardware changes are required.
Microprocessor-base controllers are more easily
connected to the computer network within an
organization. This allows designer to enter program
changes and read current system status from their
desk terminals.
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When buying or ordering an MBC the following is a step by
step procedure to simplify the process.
1. Specify Digital Inputs - List the Digital inputs and their
voltage ranges.
2. Specify Analog Inputs - List the Analog inputs and their
voltage swings.
3. Specify Data Inputs - List any Data inputs.
4. Specify On/Off Outputs - List On/Off outputs and their
current ratings.
5. Specify Proportional Outputs - List Proportional outputs
and their current ratings.
6. Specify Data Outputs - List the Data outputs.
7. Describe the desired MBC operation. Describe any
monitoring, limiting or automation to be done by the MBC
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Spark timing
Air Fuel Mixture Solenoid
Fuel injection valve
Engine speed
Crankshaft position
Spark timing feedback
Engine temperature
Throttle position
Mass air flow
Micro
processor
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It has Analog and digital circuits, sensors,
actuators, and microprocessors.
Working
User places an original in a loading bin and pushes a
button to start the process.
The original is transported to the platen glass
A high intensity light source scans the original and
transfers the corresponding image as a charge
distribution to a drum.
Blank piece of paper is retrieved from loading
cartridge, and image is transferred onto the paper
with an electrostatic deposition of ink toner powder
that is heated to bond to the paper.
A sorting mechanism then delivers the copy to an
appropriate bin.
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Control
Analogue circuits control the lamp, heater, and other power
circuit.
Digital circuit controls digital display, indicator lights,
buttons, switches forming the user interface.
Other digital ckt include logic ckts and microprocessor that
coordinates all the functions of the machine.
Sensors
Optical sensors and micro switches detect the presence on
absence of paper, its proper positioning, and whether or
not door and latches are in proper position.
Encoders used to track motor rotation.
Actuators
(servo/stepper) load and transport the paper, turn the drum
and index the drum.
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Actuators
Servo Motors
Sensors
IR Sensor for obstruction detection
Bumper Sensor for obstruction detection
Compass, for orientation detection
Accelerometer, for tilt detection
Ultrasonic sensor, for range detection.
Micro Controller
BASIC Stamp 2 module
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Growth in mechatronic systems will be fueled by the
growth in the constituent areas.
Advancements in traditional disciplines fuel the growth
of mechatronics systems by providing enabling
technologies.
For example, the invention of the microprocessor had
a profound effect on the redesign of mechanical
systems and design of new mechatronics systems.
We should expect continued advancements in cost-
effective microprocessors and microcontrollers, sensor
and actuator development enabled by advancements in
applications of MEMS, adaptive control methodologies
and real-time programming methods, networking and
wireless technologies, mature CAE technologies for
advanced system modeling, virtual prototyping, and
testing.
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The continued rapid development in these areas will
only accelerate the pace of smart product development.
The Internet is a technology that, when utilized in
combination with wireless technology, may also lead to
new mechatronic products.
While developments in automotives provide bright
examples of mechatronics development, there are
numerous examples of intelligent systems in all walks
of life, including smart home appliances such as
dishwashers, vacuum cleaners, microwaves, and
wireless network enabled devices.
In the area of human-friendly machines we can
expect advances in robot-assisted surgery, and
implantable sensors and actuators.
Other areas that will benefit from mechatronic advances
may include robotics, manufacturing, space technology,
and transportation.
The future of mechatronics is wide open.
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Mechatronic system designs are complex by nature, and
are becoming more complex day by day.
As the system design grow in overall size to
accommodate ever increasing demands for functionality
and performance, these design must integrate analog
and digital hardware, as well as the software that
controls them.
Mechatronic systems behavior is determined by
interdependencies between different components.
Therefore, an integrated and interdisciplinary
engineering approach is necessary.
For this reason, engineers must be assisted by tools
which allow a systems analysis with respect to
capabilities, capacities and behavior without really
constructing the system.
This necessitates an appropriate modeling and
simulation tool for mechatronic systems.
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