Ross Bennett

Mechatronics Hnc Assignment

Howard Mills
1)
A) Explain the meaning of a mechatronic system
Mechatronics is a combination of mechanical engineering, electronic engineering and
software engineering working in synergy. The word itself is a portmanteau of 'Mechanics'
and 'Electronics'.
W. Bolton States A mechatronic system is not just a marriage of electrical and
mechanical systems and is more than just a control system; it is a complete integration
of all of them.
A system can have many electro-mechanical components. Mechatronics use a closed
loop control system this means the output has a effect on the input signal. to be a
Mechatronic system it must have the following elements; Reference Value, Control Unit,
Correction Unit, Process, Controlled Variable, Measuring Device and Error Signal. Below is
a black diagram showing the elements in the correct order.
Figure 1 (National Instruments, 2012) http://zone.ni.com/reference/enXX/help/371894G-01/lvsimconcepts/sim_c_models/

Mechatronic Systems have microcomputers to ensure smooth functioning and higher

dependability. The sensors in these systems absorb signals from the surroundings; react
to these signals using appropriate processing to generate acquired output signals. A Few
examples of Mechatronics System are automated vehicles, robots, digitally controlled
engines and machine tools with self-adaptive tools, and some home appliances (e.g.
Washers, dryers, etc.)
A few advantages of using a mechatronic system would be; lower cost, ability to perform
precise movements, extremely reliable, compact, improved dynamic operations and
complexity of mechanical elements moved to software.

b) Use the above definition to explain which of the following devices are
mechatronic;
i.

An industrial robot is a prime example of a mechatronics system; it includes

aspects of electronics, mechanics and computing, so it can carry out its day to
day jobs.
It has 4 rotational axis because of this it is able to work at high speeds and still
be extremely precise which makes it excellent for manufacturing components.
It is seen as a mechatronic system because it uses motors to rotate the robot

Ross Bennett
Mechatronics Hnc Assignment
Howard Mills
to function correctly. It also has a microcontroller that tells the Robot what it
must do. It acts as the Reference Value and Control unit for the Robot to make
sure it is performing the correct task.
The axis moving from the motor is classed as the correction unit. With the
process the being whatever the robot is manufacturing. The output is the
controlled variable which is to perform the task required. It is then finally
measured to ensure the process has been complete and if it has then it will be
moved onto the next process. The robot moves using absolute encoders, these
rotational absolute encoders will tell the microprocessor what position the
robot arm is in .
Figure 2 http://www.eurobots.net/Scara-Robots-robots-MitsubishiMelfa-RH-10AH85-p68-en.html

ii.

A television produces a series of tiny dots on a screen that, when seen as a

whole, appear as an image and operate with an analogue signal. It is clear to
me why a television does not fall into a mechatronic category. It does not
require any sort of mechanical system to produce its output.
As technology has advanced and for the process of explaining why it isnt I
have choose a LCD (liquid crystal display) television. These TVs are more
compact and have crisper pictures than their cathode-ray counterparts
because they use a thin grid of pixels to create images rather than a vacuum
tube. It consists of a power supply where the voltage is dropped down using a
transformer for a voltage high enough to run the televisions operations. The
television holds a low voltage when it is turned off so when a remote is
switched to turn the tv on it then gos back to its ordinary voltage. This is
carried out by a PCB which controls all of the functions the tv needs to
operate. It also sends information and commands to operate the televisions
output (the program whats on).
Because of the parts explained and there is clearly not mechanical output I
deem this to be a non-mechatronic system.

Ross Bennett
Mechatronics Hnc Assignment
Howard Mills
Figure 3 http://www.cnet.com/news/bringing-a-flat-screen-tv-backfrom-the-dead/

iii.

This is not a mechatronic system as it we have no negative feedback to the

input that would try and correct the mistake. So it does not fit the mechanical
design system because it is not following the correct mechatronic cycle. Below
I have described the process step by step
Firstly the paddle is the mechanical component; this is used to direct the
components dependent on the specifications on the component. It is done via
a mechanically by a paddle moving back and forth through a motor/actuator
causing it to open or close for sizes.
There is a multiple electronic components which are used to carry out this
task. There is the PLC, this is the brains of the operation it controls the whole
process of the conveyer system and collects all information received form the
micro switches. The micro switches sense the sizes of the components sends
that information to the plc and then the flapper moves the component to the
correct channel.
Although the system its self has a motor/actuator, a micro switch and a plc
you would assume that the outcome it mechatronic. Although it does have
mechanical and electronic principle it does not follow the cycle a proper
mechanical system would operate, which is when the process is finished the
information is sent back to be measured. So overall it does have mechatronic
principles but it does not follow the cycle a usual mechatronic system would
carry out.

2)

Ross Bennett
Mechatronics Hnc Assignment
Howard Mills
The system I am choosing surface mount machine (SMT), I will explain how the SMT
works what has been integrated into the system which makes it a Mechatronic system.

SMT machines are used within the manufacture of PCBs (electronic circuit boards). The
surface mount components are far too small to be manually placed so automated pick
and place is used within the machine to eliminate the need for manual assembly.
The machine firstly needs to be programmed to complete the task this is where the
operator would fill in the required information for each component needing to be placed
via the 4 independent axis (up/down/left/right). The machine has a total of 10
manipulators which can pick up and move up to 85k components per hour to their
correct precise position on the printed circuit board. Each manipulator is controlled using
sensors and actuators which send a feedback signal back to the computer. These
movements are actuated by the use of pneumatic cylinders operated by solenoid
controlled valves with limit switches to indicate when a motion is completed. Each
component is placed in the correct position by having the PCB go along a conveyer belt
where The PCB is clamped, a camera is placed on the pick and place head which
photographs the fiducial marks. The fiducial marks ensure the base of the printed circuit
board is in the correct place so that when the component is placed in the position the
program has told it to go it will be placed down there. The nozzles pick up each
component from the feeders, rotate them to the correct orientation using rotational
absolute encoders and then place them on the appropriate pads on the PCB. Each nozzle
uses a small gripper which can be opened or closed by a piston in a linear cylinder
extending or retracting.
Once finished this step the machine then goes on to check that each component was
placed correctly and that no components are missing. The machine then takes a
photograph/visually scanning the board using high definition cameras, so the machine is
able to build up a picture of the board, this image is then captured and compared to a
golden sample which the machine has stored within it memory. Using this comparison the
machine is able to spot any defects before the solder is applied, so that if any component
is missing, put on the wrong way or even placed out of tolerance. The machine gos back
and moves the component to the correct location and then it checks for defects again.
Once the pcb board has passed this stage it will move on to be soldered within a oven.
The ovens temperature is controlled by thermocouples. These thermocouples ensure the
oven isnt going over the required temperature to solder the components on the board,
since if the oven is to hot the pcb can be burned or damaged. and then follow the AOI
again to check for any solder bridges or dry joints.
The SMT has all of the elements a Mechatronic systems needs which are Reference Value,
Control Unit, Correction Unit, Process, Controlled Variable, Measuring Device and Error
Signal

Ross Bennett
Mechatronics Hnc Assignment
Howard Mills

3)
ABS anti braking system

Each wheel has a sensor and its own valve. It has a ECU which controls
the process of the valves which the sensors pick up. A ABS pump is used
to increases the pressure to brake.

Control Unit - ECU Controller

Correction Unit - Pressure Valves
Process - The Braking,
Controlled Variable - Speed
Measuring Device - Speed Sensor
Reference Valve - ECU Controller
Error Signal - Speed Sensor

Ross Bennett
Mechatronics Hnc Assignment
Howard Mills

Traction Control Through Boost Reduction

Some cars can use a reduction in boost to regain traction for the car. Once
the traction is gained it is able to accelerate again.

Control Unit - ECU Controller

Correction Unit - Turbo
Process - Slowing wheel
Controlled Variable - Speed
Measuring Device - Speed Sensor
Reference Valve - ECU Controller
Error Signal - Speed Sensors

Escalator lift

They have many sensors to detect the position and the speed it is
travelingIt has many actuators, the most important of which is the motor
which pull the elevator up or down. Sensors within the lift will check the
position to see wether it is moving or not. This will then tell the motor to
move the elevator to the position/level which has been selected by the
end user. Once it has reached its destination it is checked by a sensor to
check it is in the correct position.

Control Unit - controller or the button board within the escalator

Correction Unit - motor
Process - Elevation up/down
Controlled Variable - the position of the lift
6

Ross Bennett
Mechatronics Hnc Assignment
Howard Mills

Measuring Device - Sensors

Reference Valve - height/position
Error Signal - blocked doors/ wrong position /sensors.

Oven
The temperature control in a oven has a wide range of processes. These
require control of the temperature so it does not go to hot or cold. The
heat is found out by using sensors within the oven.

Control Unit - Micro Controller

Correction Unit - Element Process Heating and baking of products
Controlled Variable - The ovens temperature.
Measuring Device - Temperature Probes
Reference Valve - Controller
Error Signal - Temperature Probes.

Ross Bennett
Mechatronics Hnc Assignment
Howard Mills

Bibliography
National Instruments, 2012. [Online]
Available at: http://zone.ni.com/reference/en-XX/help/371894G01/lvsimconcepts/sim_c_models/
[Accessed 2014].