Introduction

To
Mechatronics

Prof C.S.P.Rao

Dept of Mechanical Engineering

N I T, Warangal
Introduction

The word mechatronics was first introduced by the

senior engineer of a Japanese company; Yaskawa,
in 1969, as a combination of "mecha" of
mechanisms and "tronics" of electronics, and the
company was granted trademark rights on the
word in 1971.
Mechatronics - Definition
Mechatronics is synergistic integration of mechanical
engineering, electronics and intelligent computer control in
design and manufacture of products and processes.
 Evolution of Mechtronic Systems
The development of mechatronics has gone through three
stages.

The first stage corresponds to the years when this term

was introduced. During this stage, technologies used in
mechatronic systems developed rather independently and
individually.

During the second stage, i.e., with the beginning of the

eighties, a synergistic integration of different technologies
started taking place, the no-table example is
optoelectronics (i.e. an integration of optics and
electronics). The concept of hardware/software co-design
also started in those years.
The third and the last stage can also be considered as the
beginning of the mechatronics age since early nineties.

The most notable aspect of the third stage is the increased

use of computational intelligence in mechatronic products
and systems. It is due to this development that we can now
talk about Machine Intelligence Quotient (MIQ).

Another important achievement of the third stage is the

possibility of miniaturization of components; in the form
of micro actuators and micro sensors (i.e. micro
mechatronics).
Key elements of Mechatronic System
 Actuators

Most mechatronic systems involve motion or

action of some sort.
Actuators are the devices used to produce
this motion or action.
This motion or action can be applied to any
thing from a single atom to a large
articulated structure.
It is created by a force or torque that results
in acceleration and displacement.
 Actuators produce physical changes such as linear
and angular displacement.

They also modulate the rate and power associated

with these changes.

An important aspect of mechatronic system design

is selecting the appropriate type of actuator.

Types of actuation systems

Pneumatic and hydraulic actuation systems
Mechanical actuation systems
Electrical actuation systems
Sensors

A sensor is an element in a mechtronic or

measurement system that acquires a
physical parameter and changes it into a
signal that can be processed by the system.

Often the active element of a sensor is

referred to as a transducer.
 Transducers are grouped according to what they are
being used to measure

• Displacement position and proximity

• Velocity and motion sensors

• Force

• Fluid pressure

• Liquid flow

• Liquid level

• Temperature

• Light sensors
 Necessity for Input Signal Conditioning

The transducers which converts physical quantities

like temperature, displacement etc., into currents
or voltages and gives them in the form of analog
signals, which are continuous and time varying.
Often the signal from the traducers may be –
Too small (in milli volts)
Too noisy (due to electromagnetic interference)
Containing wrong information (due to poor
transducer design)
Having DC offset (due to transducer and
instrumentation design)
Many of these these problems can be
remedied and the desired signal information
can be extracted through appropriate analog
signal processing.

The simplest and the most common form of

signal processing is amplification, where
the magnitude of the signal is increased.
 Need for digital signal

Analog signal are continuous and time

varying, whereas digital signals have only
two stages: high and low.
Since computers and microprocessors
require digital signals, any application
involving computer measurement or
control requires analog to digital
conversion.
 Control Architectures

To obtain completeness in the integration of

mechanical devices
sensors
signal and
power electronics
into the most advanced mechatronic systems,
microprocessor based control systems must be
included.
Hierarchy of basic control approaches

Analog circuits
Digital Circuits
PLC’s
Microcontroller
Single Board Computer
Personal Computer.
Copy Machine – A typical example of a
Mechatronic System

An office copy machine consists of analog and

digital circuits, sensors, actuators and
microprocessors.

Analog circuits control the lamp, heater and other

power circuits in the machine.

Digital circuits controls the digital displays,

indicator lights, buttons and switches forming the
user interface.
Optical sensors and micro switches detects the
presence or absence of the paper, its proper
positioning and whether or not doors and latches
are in their correct positions.

Other sensors include encoders used to track the

motor rotation.

Actuators include servo and stepper motors that

load and transport the paper, turn the drum and
index the sorter.

Microprocessors coordinate all the functions in the

machine
Examples of Mechatronic Systems (MS)

computer disk
drive

clothes washer
 DESIGN
OF
MECHATRONIC
SYSTEMS
STAGES IN DESIGN PROCESS

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

TRADITIONAL DESIGN VS MECHATRONICS DESIGN

:
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.

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.
 THERMOSTAT

TRADITIONAL DESIGN MECHATRONICS DESIGN

 TRADITIONAL THERMOSTAT DESIGN

SECTIONAL VIEW COMPONENTS OF THERMOSTAT

CONVERSION TO MECHATRONIC DESIGN
ADVANTAGES OF MECHATRONICS DESIGN

HIGH RESOLUTION & ACCURACY

REDUCES HOUSE HOLD HEATING COST

SELF CALIBRATING

FLEXIBLE DESIGN

ENVIRONMENTAL FRIENDLY
TINY MCUs IN SWITCHES & POTENTIOMETERS
MECHATRONIC SYSTEMS
CASE STUDIES
 TIMED SWITCH

Consider a simple requirement for a device which

switches on some actuator, e.g. a motor, for some
prescribed time.
A mechanical solution could involve a rotating cam The
cam would be rotated at a constant rate and the cam
follower used to actuate a switch, the length of time for
which the switch is closed depends on the shape of cam.
 MECHATRONICS SOLUTION

A PLC arrangement could involve

the arrangement shown in figure
with the given ladder program. This
would have the advantage over the
rotating cam of having off and on
times which can be adjusted by
purely changing the timer preset
values in the program where as
different cam is needed if the times
have to be changed with the
mechanical solution.
 MECHATRONICS SOLUTION
A microprocessor-based solution could involve a microprocessor with
a memory chip and input/output interfaces. The program is then used
to switch an output on and off after some time delay with the time
delay being produced by a block of program in which there is a timing
loop. This generates a time delay by branching round a loop the
number of cycles required to generate the requisite time, in
assembly language:

DELAY LDX #F424 F424 is number of loops

LOOP DEX
BNE LOOP
RTS
o DEX decrements the index register, and this and BNE, branch if not
equal, each take 4 clock cycles. The loop thus takes 8 cycles and
there will be n such loops until 8n+3+5 gives the number F424 (LDX
takes 3 cycles and RTS takes 5 cycles). In C we would write the
program lines using the while function.
An alternative to using a loop is to use a
timer module, e.g. 555, with the
microprocessor.

With the 555 timer the timing intervals

are set by external resistors and
capacitors.

Figure shows the timer and the external

circuitry needed to give an on-output
when triggered, the duration of the
on-output being 1.1RC.

Large times need large values of R and

C. R is limited to about 1 Mc otherwise
leakage becomes a problem, and C is
limited to about 10 μF if electrolytic
capacitors with problems of leakage and
low accuracy are to be avoided. Thus the
circuit shown is limited to times less than
about 10 s. the lower limit is about R= 1
kc and C= 100pF, i.e. times of a fraction
of a millisecond. For longer times, from
16 ms to days, an alternative timer such
as the ZN1034E can be used.

555 timer
 (a) Generating 2 MHz internal clock
Another possibility is to use the timer system in a
microcontroller such as MC68HC11.

The timer system is based on a 16-bit counter TCNT

operating from the system E-clock signal (Figure (a)).

The system E-clock can be pre-scaled by setting bits in the

timer interrupt mask register 2 (TMSK 2), address $1024
(Figure (b)).

The TCNT register starts at $0000 when the processor is reset

and counts continuously until it reaches the maximum count
of $FFFF.

On the next pulse it overflows and reads $0000 again. When it

overflows it sets the timer overflow flag TOF (bit 7 in
miscellaneous timer interrupt flag register 2, TFLG2 at (b) Pre-scaled factor
address $1025).

Thus with a pre-scale factor of 1 and an E-clock frequency of

2 MHz, over flow occurs after 32.768

One way of using this for timing is for the TOF flag to be
watched by polling. When the flag is set, the program
increments its counter. The program then resets the flag, by
writing a 1 to bit 7 in the TFLG2 register. Thus the timing
operation just consists of the program waiting for the
required number of overflag settings.
A better way of timing involves the use of the output-
compare function.

Port A of the microcontroller can be used for general

inputs or outputs or timing functions.

The timer has output pins, OC1,OC2,OC3,OC4 and OC5,

with internal registers TOC1, TOC2, TOC3, TOC4 and
TOC5.

We can use the output-compare function to compare the

values in the TOC1 to TOC5 registers with value in the
free running counter TCNT. This counter starts at 0000
when the CPU is reset and then runs continuously.

When a match occurs between register and the counter

then the corresponding OCx flag bit is set and output
occurs through the relevant output pin.

The Figure shown illustrates this. Thus by programming

the TOCx register, so the times at which output occur can
be set. The output-compare function can generate timing OUTPUT COMPARE
delays with much higher accuracy than the timer
overflag.
 WINDSCREEN-WIPER MOTION

Consider a requirement for a device which will oscillate

an arm back and forth in an arc like a wind screen
wiper. A mechanical solution is shown in the Figure
below . Rotation of arm 1 causes arm 2 to impart an
oscillatory motion to arm 3.

WIPER MECHANISM
 MECHATRONICS SOLUTION
An alternative solution is to use a
stepper motor.

Figure below shows how a

microprocessor with a PIA, or a
microcontroller, might be used
with a stepper.

The input to the stepper is

required to cause it to rotate a
number of steps in one direction
and then reverse to rotate the
same number of steps in one
direction and then reverse to
rotate the same number of steps
in the other direction.
 If the stepper is to be in the ‘ full-step’ configuration then the outputs need to be as shown in
Table below. Thus to start and rotate the motor in a forward direction involves the sequence
A, 9, 5, 6 and then back to the beginning with 1 again. To reverse we would use the sequence
6, 5, 9, A and then back to begin with 6 again.
Step Bit 3 Bit 2 Bit 1 Bit 0 Code
1 1 0 1 0 A
2 1 0 0 1 9
3 0 1 0 1 5
4 0 1 1 0 6
1 1 0 1 0 1

If ‘ half-step’ configuration is used then the outputs need to be as

shown in Table below.
Step Bit 3 Bit 2 Bit 1 Bit 0 Code
1 1 0 1 0 A
2 1 0 0 0 8
3 1 0 0 1 9
4 0 0 0 1 1
5 0 1 0 1 5
6 0 1 0 0 4
7 0 1 1 0 6
8 0 0 1 0 2
1 1 0 1 0 A
 Where there are many steps involved a simpler program is to increment a
counter with each step and loop until the counter value reaches the required
number. Such program would have the basic form of:

 Advance a step

 Jump to time delay routine to give time for the step to be completed.

 Increment the counter.

 Loop or repeat the above with successive steps until the counter indicates the
requisite number of steps completed in the forward direction.

 Reverse direction

 Repeat the above for the same number of steps in reverse directi
 Integrated circuit SAA 1027 for stepper motor
Integrated circuits are available for step
motor control and their use can simplify
the interfacing and the software.

Figure shows how such a circuit can be

used.

All that is then needed is the requisite

number of input pulses to the trigger, the
motor stepping on the low-to-high
transition of a high-low-high pulse.

A high on the rotation input causes the

motor to step counter-clockwise while a
low gives clockwise rotation.

Thus we just need one output from the

microcontroller for output pulses to the
trigger and one output to rotation. An
output to set is used to reset the motor
back to its original position.
 BATHROOM SCALES or
SIMPLE WEIGHING MACHINE
The main requirements are that a person can
stand on a platform and the weight of that person
will be displayed on some form of readout. The
weight should be given with reasonable speed and
accuracy and be independent of where on the
platform the person stands.

One possible solution is to use the weight of the

person on the platform to deflect an arrangement
of two parallel leaf springs (Figure (a)). With such
an arrangement the deflection is virtually
independent of where on the platform the person
stands.

The deflection can be transformed into movement

of a pointer across a scale by using the
arrangement shown in Figure (b). A rack-and-
pinion is used to transform the linear motion into a
circular motion about a horizontal axis. This is
then transformed into a rotation about a vertical
axis, and hence movement of a pointer across a
scale, by means of a bevel gear.
 MECHATRONICS SOLUTION
It involves the use of a microprocessor.

The platform can be mounted on load cells

employing electrical resistance strain gauges.
When the person stands on the platform the
gauges suffer strain and change resistance.

If the gauges are mounted in a four-active-

arm Wheatstone bridge then the out-of-
balance voltage output from the bridge is a
measure of the weight of the person.

This can be amplified by a differential

operational amplifier. The resulting analog
signal can then be fed through a latched
analog-to-digital converter for inputting to
the microprocessor, e.g. the Motorola 6820.

The adjacent Figure shows the input

interface. There will also be a need to provide
a non-erasable memory and this can be
provided by an EPROM chip, e.g. Motorola
2716. The output to the display can then be
taken through a PIA, e.g. Motorola 6821.
If a microcontroller is used then memory is present within the single
microprocessor chip, and by a suitable choice if a microcontroller, e.g. M68HC11,
the analog-to-digital conversion can be obtained for the inputs.
The system then becomes: strain gauges feeding through an operational amplifier
a voltage to the port E (the ADC input) of the microcontroller, with the output
passing through suitable drives to output through ports B and C to a decoder and
hence a LED display (Figure below).
A PICK-AND-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 Figure (a)
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 (b)
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.
 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.
 MECHATRONICS SOLUTION
PLC connections Ladder diagram
 AUTOMATIC CAMERA
The basic features of the Canon EOS model, automatic, auto-focus,
reflex cameras is shown in the Figure (a) .

The cameras have interchangeable lenses.

There is a main microcontroller in the lens housing, the two

communicating with each other when a lens is attached to the camera
body.
BLOCK DIAGRAM OF THE ELECTRONIC SYSTEM
The metering sensor has six light sensors as
shown in the Figure.

Signal conditioning is used to obtain the

average value of C1, C2, C3, and C4; the A, B
and average C value are then analysed to find
the required exposure value. This, for
example, reveals whether the scene is a scene
with a relatively constant luminosity or
perhaps a close up of a person so that there is
bright central zone surrounded by a dark
background.

The type of program that is used is:

If B is equal to A and C minus B is

less than 0

then exposure set on value of A

if B is equal to A and C minus B is 0

then exposure set on value of C

For the main microcontroller

Send start command to lens microcontroller

Take input from range sensor
Calculate lens movement required
Send lens movement data to lens microcontroller
Wait for verification of lens movement from microcontroller
Send in-focus signal to viewfinder display

For the lens microcontroller

Wait for start command from main microcontroller

Determine the initial lens position
Wait for lens movement data from main microcontroller
Read lens movement data
Calculate new lens position
While lens is not in new position drive the motor
Send verification signal of in-focus to main microcontroller
This information is translated by the
microcontroller into an appropriate shutter
speed and aperture value. If the camera is
operated with the shutter speed preselected
by the photographer then only the aperture
value is supplied; similarly if the aperture is
preselected then only the shutter speed is
supplied.

The range sensor has two 48-bit linear

arrays of photo detectors. The light from
the object, after passing through the camera
lens, falls on this array (Figure). When the
image is in focus the spacing of the images
on the detector array is a particular value,
the spacing deviating from this when the
image is out of focus.

The amount of this deviation is used to give

an error signal, which is fed to the lens
microcontroller and used to give an output
to adjust the focusing of the lens. An
encoder is used to provide feed back of this
adjustment so that the microcontroller
knows when the focusing has been
completed. The program is thus of the
form: Automatic focusing
The diaphragm drive system is a stepper motor,
which opens or closes a set of diaphragm blades.

The focusing involves two forms of drive, the arc

form drive and the ultrasonic motor. The arc form
drive uses a brushless permanent magnet
d.c.motor, Hall sensors being used to detect the
position of the rotor.

The drive from the motor is transmitted through

gears to move the focusing lens along the optical
axis. The ultrasonic motor has a series of
piezoelectric elements in the form of a ring (Figure
(a). When a current is supplied to the piezoelectric
element it expands or contracts according to the
polarity of the current.

By switching the current to the piezoelectric

elements in the appropriate sequence a
displacement wave can be made to travel around
the piezoelectric ring of elements in either a
clockwise or counter-clockwise direction and
consequently rotate a rotor which is in contact
with its surface, hence driving the focusing element

The control system for the ultrasonic motor is of

the form shown in Figure (b)
 CAR ENGINE MANAGEMENT

The modern car is likely to include many

electronic control systems involving micro
controllers, the engine control system being
one.
Figure below shows a generalized block diagram of such a system, its
aim being to ensure that the engine is operated at its optimum settings.
The system consists of sensors supplying, after suitable signal
conditioning, the input signals via drivers to actuate actuators. Figure
below shows some of these elements in relation to an engine; only one
cylinder is being shown.
 BAR CODE ENCODER
The familiar scene at the check-out of a supermarket is of the
purchases being passed in front of a light beam or a hand-held wand
being passed over the goods so that the bar code can be read and the
nature of the purchase and hence its price automatically determined.
The code consists of a series of black and white bars of varying widths.
The bar code represents a series of numbers.

There is a prefix which identifies the coding scheme being used; this is a single
digit for the regular Universal Product Coding (UPC) used in the United
States and two digit for the European Article Number (EAN) scheme used in
Europe.

The UPC uses a 0 prefix for grocery and a 3 for pharmaceuticals. The EAN
prefix is from 00 to 09 and is such that the UPC code can be read within the
EAN code.

This is followed by five digits to represent the manufacturer, each

manufacturer having been assigned a unique number.
This brings up the center of the code pattern, which is identified by two taller
bar patterns.

The five-digit number that then follows represents the product. The final
number is a check digit, which is used to check that the code has been
correctly read.

A guard pattern of two taller bars at the start and end of the bar pattern is used
to frame the bars.
Each number is coded as seven 0 or 1 digits.

The codes used on either side of the centerline are different so that the direction of the scan
can be determined.

To the right the characters have an even number of 1s and so even parity; for UPC, to the
left an odd number of 1s and so odd parity; the EAN coding for the left being a mixture.

Table below shows the UPC and EAN codings, UPC being the left A coding and the EAN
using both left A and left B character codes.

Decimal number Left A Left B Right

Characters Characters Characters

0 0001101 0100111 1110010

1 0011001 0110011 1100110
2 0010011 0011011 1101100
3 0111101 0100001 1000010
4 0100011 0011101 0011100
5 0110001 0111001 0001110
6 0101111 0000101 1010000
7 0111011 0010001 1000100
8 0110111 0001001 1001000
9 0001011 0010111 1110100
Each 1 is entered as a dark bar and
thus the right-hand character 2 would
be represented 1101100 and, with the
adjacent dark bars run together, it
appears as a double-width dark wide
bar followed by a narrow space and
then another double-width dark wide
bar followed by a double-width space.
This is illustrated in Figure below.

The guard pattern at the ends of the

code represents 101 and the central
band of bars is 01010.
PROCEDURE FOR USING CHECK CODE DIGIT

Starting at the left, sum all the characters, excluding the

check digit, in the odd positions, i.e. first, third, fifth, etc. and
then multiply the sum by 3.

Starting at the left, sum all the characters in the even

positions.

Add the results of steps 1 and 2. The check character is the

smallest number which when added to this sum produces a
multiple of 10
 INVERTED PENDULUM SYSTEM: ROTARY
AND ARM-DRIVEN

The inverted pendulum is a popular mechatronic application that

exists in many different forms. The common thread among these
systems is their goal:
to balance a link on end using feedback control.
Two rather challenging inverted pendulum systems are the
rotational and the arm-driven systems.

These use a link rotating about an axis to balance a second link on end.
In the rotary (horizontal) configuration, the first link, driven by a
motor, rotates in the horizontal plane to balance a pendulum link,
which rotates freely in the vertical plane. The arm-driven (vertical) or
“stick-on-a-stick” configuration uses a driven link rotating in the
vertical plane to balance the pendulum link, which also rotates in the
vertical plane.
The inverted pendulum system is unique in that it can be transformed from
the horizontal to vertical configuration by replacing the links and setting
the base on its side, as shown in Figure

(a) (b)
Figure: Inverted Pendulum System Configurations: (a) Horizontal and (b) Vertical
Rotary inverted pendulum dynamic system investigation:

Physical System : It consists of two links: a motordriven

horizontal link and an un-actuated vertical pendulum link. The
horizontal link is driven by a permanent-magnet, brushed DC
motor. A DC power supply together with a pulse-width-
modulated (PWM) servo-amplifier, operating in the current
mode, supply power to the motor.

Angular position and velocity of the two links are measured

with two rotary incremental optical encoders having a
resolution with quadrature decoding of 2048 pulses per
revolution.
 A slip-ring assembly, mounted between the housing and the
motor shaft, is used to connect power to the pendulum
optical encoder and read the signal from the three channels
of the encoder. The horizontal link is counter-weighted and
there are leveling screws on the housing base. System
testing for parameter identification and control system
design is performed in a MatLab / Simulink / dSpace real-
time control environment. This allows for rapid control
system development and testing.

Physical Model
Several simplifying assumptions were made in developing a
physical model:
1. rigid links
2. two degrees of freedom
3. negligible sensor dynamics
Control System design: Balancing and swing-up

The swing-up control is based on the work of Astrom and

Furuta and the balancing controller is a full state-feedback
regulator. The swing up controller calculates the total
system energy based on the kinetic energy of both links, and
the potential energy of the pendulum.

This calculated value is compared to a defined quantity of

energy when the pendulum is balanced. The difference
between desired energy and actual energy is multiplied by
an "aggressivity" gain and applied to the motor.
Figure : MatLab/Simulink Block Diagram of Control System Design
 Figure : MatLab/Simulink Block Diagram of Control Selection Subsystem

The objective of the swing-up control exercise is to move the system from the
stable equilibrium position to the unstable equilibrium position. Hence, energy
has to be added to the system to achieve this swing-up action. The
manipulated input to realize the above idea is given by the following control
law:

V = KA (E – EO) sign(ɑcos ɑ)
The velocity term causes the input
to change directions when the
pendulum stops and begins to swing
in the opposite direction. The cosine
term is negative when the pendulum
is below horizontal and positive
above horizontal. This helps the
driven link to get under the
pendulum and catch it as shown in
Figure below. By controlling on
energy feedback, the system
automatically stops inputting excess
energy and allows the system to
coast to a balanced position.
Figure : Sign function effect on swing up
From Figure below, when the remaining potential energy
required is equal to the kinetic energy, the feedback will
become very small and the pendulum will coast to vertical
position.

Figure : Swing up diagram

 Figures below show the simulation results for the swing-up and balance
controllers. The angles plotted are normalized angles.

Figure : Normalized Pendulum angle Versus Time Figure : Normalized Driven Link angle Versus Time
DESIGN OF AN ATOMIC FORCE MICROSCOPE
The atomic force microscope (AFM) is a mechatronic instrument that
has had a revolutionary impact in the last decade on the ability to
image the topography of surfaces in the micron to subnanometer
range. AFM’s form images of surface properties by scanning a
cantilevered probe with a sharp tip over the surface of a sample in
an x-y raster pattern.
The deflection of the probe caused by repulsive (or
attractive) forces between atoms of the tip and sample is
used to quantitatively map the topography or determine
other properties of the surface .

AFM’s are used extensively by researchers across the

disciplines of physics, chemistry, biology, material science,
and others to image surface properties, measure
fundamental force interactions, and understand
mechanical properties of materials.

AFM’s are also being used as metrology instruments

particularly in the semiconductor industry.
 The main subsystems that
comprise an AFM are:

 the cantilever probe,

 the scanner,

 the deflection sensing system,

 the controller,

 the data acquisition

the processing system, and

the mechanical assembly

Figure : Schematic diagram of an atomic force microscope (AFM).

Figure (a) shows AFM
cantilevers: shows typical
rectangular or triangular
shapes of cantilevers. The
rectangular cantilever on the
left is 200-_m long and 20-
_m wide.

Figure (b) and (c) shows a

close-up view of the tip of a
cantilever. AFM cantilevers
are made using IC
fabrication and silicon
micromachining processes
Figure : Cantilever deflection
measurement approaches:
(a) shows the optical lever
approach, where deflection of the
cantilever causes the reflected
laser beam to illuminate one
photodetector cell more than the
other. The motion of the beam,
hence the deflection of the
cantilever, can be quantified by
taking the difference of the
photocurrents from the two cells
and
(b) shows the piezoresistive
cantilever approach, where a
specially fabricated cantilever is
connected as one leg of a
Wheatstone bridge. The
deflection of the cantilever is
sensed by a change in the output
voltage of the bridge.
 Mechatronic Design of the Hewlett-Packard DESKJET
560C Printer
The mechatronic related design objectives for this
printer are shown in Table below.
 MECHATRONIC DESIGN

Figure illustrates the

mechatronic design of the
printer.

The printer uses three motors:

a dc motor drives the scanning
carriage, one permanent
magnet “tin-can” stepper
motor drives the paper feed
system, and a second
permanent magnet stepper
motor actuates the print
Figure : HP deskjet Mechatronic System
cartridge service station.
All three of these motors are controlled with less than
10% of the bandwidth of an inexpensive 8-bit Z-80
microprocessor

Figure : Control System Block Diagram

Modern Trends of MS Development

Machine-tool construction and

equipment for automation of
technological processes;
Robotics;

Office equipment;
Computer facilities;
Photo and video
equipment;
Modern Trends of MS Development
Aviation,
space and military
techniques;
Motor car construction
Modern Trends of MS Development
Simulators for training of
pilots and operators;
Show-industry;
Control and measuring
devices and machines;
Micro machines;
Non-conventional vehicles.
Fundamental Problems
Structural integration of mechanical, electronic and
information departments into a uniform creative staff;
Education and training of engineers specialized in
mechatronics and managers able to organize integration and
supervise work of strictly specialized experts with different
qualifications;
Integration of information technologies from various
scientific and technical fields into a uniform toolkit to provide
computer support of mechatronic problems;
Standardization and unification of all used elements and
processes at designing and manufacturing MS.
Levels of Mechatronic Systems’
Integration
The First Level

conveyors,
rotary tables,
auxiliary manipulators
 Levels of Mechatronic Systems’
Integration
The Second Level

operated power machines (turbines

and generators),
machine tools and industrial robots
with numerical program
management
Levels of Mechatronic Systems’
Integration
Synthesis of new precise information and
The Third Level measuring high technologies gives a basis
for designing and producing intellectual
mechatronic modules and systems.