Introduction to Mechanical Engineering

Module-5
Introduction to Mechatronics and Robotics: Open-loop and Closed-loop mechatronic systems.
Classification based on robotics configuration: polar cylindrical, Cartesian coordinate and spherical.
Application, Advantages and disadvantages.
Automation in industry: Definition, types – Fixed, programmable and flexible automation, basic
elements with block diagrams, advantages.
Introduction to IOT: Definition and Characteristics, Physical design, protocols, Logical design of IoT,
Functional blocks, and communication models.

Introduction to Mechatronics and Robotics

Mechatronics

“Synergistic integration of mechanical engineering with electronics and intelligent computer control
in the design and manufacturing of industrial products and processes.”

Disciplinary Foundations of Mechatronics

1. Mechanical Engineering

2. Electrical Engineering

3. Computer Engineering

4. Information systems
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System

A system is an arrangement of or a combination of different physical components connected or

related in such a manner so as to form an entire unit to attain a certain objective

Control system

Control system is an arrangement of different physical elements connected in such a manner

so as to regulate, director command itself to achieve a certain objective

Fig: Physical System Fig: Control system

Types of control systems

1) Open loop control system

2) Closedloop control system

Open loop control system

In which the control action is independent of the output.

• It is a system in which control action is independent of output. To each reference input there
is a corresponding output which depends upon the system and its operating conditions.
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• The accuracy of the system depends on the calibration of the system.

• In the presence of noise or disturbances open loop control will not perform satisfactorily.

Example: Automatic washing machine, Bread toaster, traffic signals

Advantages of open loop system:

1. They are simple in construction and design.

2. They are economic.

3. Easy for maintenance.

4. Not much problem of stability.

5. Convenient to use when output is difficult to measure.

Disadvantages of open loop system

1. Inaccurate and unreliable because accuracy is dependent on accuracy of calibration.

2. Inaccurate results are obtained with parameter variations, internal disturbances.

3. To maintain quality and accuracy, recalibration of controller is necessary from time to

time

Applications

• Electric Hand Drier

• Automatic Washing Machine
• Bread Toaster
• Automatic Tea/Coffee Maker
• Timer Based Clothes Drier
• Light Switch
• Volume on Stereo System
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3) Closedloop control system

In which the control action is somehow dependent upon the output and are generally called as
feedback control systems.

• Is a system in which the control action depends on the output.

• In closed loop control system, the actuating error signal, which is the difference between the
input signal and the feedback signal (output signal or its function) is fed to the controller

Elements of closed loop system are:

1. Command: The command is the externally produced input and independent of the
feedback control system.

2. Reference Input Element: It is used to produce the standard signals proportional to the
command

3. Error Detector: The error detector receives the measured signal and compares it with
reference input. The difference of two signals produces error signal.

4. Control Element: This regulates the output according to the

signal obtained from error detector.

5. Controlled System: This represents what we are controlling by feedback loop.

6. Feedback Element: This element feedbacks the output to the error detector for comparison
with the reference input.

Example: Automatic electric iron, water level controller

Advantages of closed loop system:

1. Accuracy is very high as any error arising is corrected.
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2. It senses changes -in output due to environmental or parametric change, internal disturbance
etc. and corrects the same.
3. High bandwidth.
Facilitates automation.
Disadvantages
1. Complicated in design and maintenance costlier.
2. System may become unstable
Applications
• Automatic Electric Iron
• Servo Voltage Stabilizer
• Water Level Controller
• Cooling System in Car
• Air Conditioner
• Refrigerator
• Missile Launched and Auto Tracked by Radar

Robotics
An industrial robot is a reprogrammable, multifunctional manipulator designed to move materials,
parts, tools or special devices through variable programmed motions for the performance of a variety
of tasks. It can be simply thought as an artificial agent acting as a substitute for human labour. A
robot basically consists of manipulators (links and joints), guided by sensors, driven by actuators and
controlled through a programmed software to perform specific task.
Robot Anatomy:

Figure: Robot Anatomy

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It deals with the study of different joints and links and other aspects of the manipulator’s physical
construction. The robot anatomy with join-link-numbering scheme is shown in the figure above.
Robot Joints:

Figure: Robot Joints

A robotic joint provides restricted relative motion between two links of the robot. The arm andbody of
the robot are used to move and position parts or tools within the work space of the robot. The motion
in the joint can be translator or rotary about or along the axis.
Robot Links:
A link in a robot is a rigid member connecting the joints of the robot. The link maintains a fixed
relationship between the two joint axes through a kinematic function. The relationship is described by
length and twist of the link.

Common Robot Configuration:

Cartesian Configuration Robot:

Cartesian configuration robot is so called because the arm movement of the robot is designed to move
parallel to the x, y and z axis of a Cartesian coordinate system. It is capable of movingits arm to any
point linearly within a rectangular work space. Since the arm movement is linear, it also called as
rectilinear robots.
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Figure: Cartesian Configuration Robot

Advantages:
1. Simple controls due to linear movements and easy to visualize
2. High degree of mechanical rigidity, accuracy and repeatability
3. Can carry heavy loads
4. Motion of the wrist end is smoother
Disadvantages:
1. The arm movement is limited to a small rectangular work space
2. It occupies large area there by giving a low ratio robot size to operating volume
Applications:
Assembly, welding, machine loading/unloading, surface finishing, inspection, etc.
Cylindrical Configuration Robot:
Cylindrical configuration robot is so called because the arm movement of the robot is designed to
move according to the cylindrical coordinate system. It consists of a vertical column and a slide that
can move up and down along the column. The column can rotate about a vertical axis and hence is
capable of a work space that approximates a cylinder.

Figure: Cylindrical Configuration Robot

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Advantages:
1. Larger work space than Cartesian configuration
2. Robot is relatively easy to program
Disadvantages:
1. Overall mechanical rigidity is reduced because robots with a rotary axis must overcomethe
inertia of the object when rotating
2. Robots repeatability and accuracy is also reduced in the direction of rotary movement
3. It requires more sophisticated control system
Applications:
Pick and place operations, machine loading/unloading, investment casting, forging operations,
conveyer pellet transfers, assembly, coating applications, etc.

Polar Configuration Robot:

It is also referred as spherical configuration because the work space within which a robot can move its arm is a
partial sphere. It consists of a rotary base and a pivot that can be used to raiseand lower a telescoping arm similar
to the formation of an arc movement. The sliding arm canbe extended or retracted to provide the reach.

Advantages:

Figure: Polar Configuration Robot

1. It can generate large working envelope compared to Cartesian and cylindrical
2. It is simple in design and easy to program
3. Provides good weight lifting capabilities
Disadvantages:
1. Reduced mechanical rigidity
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2. More sophisticated control system is required

3. Limited vertical movement
Applications:
Die casting, injection moulding, forging, machine tool press loading/unloading, dip coating,material
transfer applications, etc.

Jointed Arm Configuration Robot:

It is similar to that of human arm, consisting two straight components corresponding to the human
forearm and upper arm mounted on a vertical pedestal that can be rotated about the base so as to
provide the robot with the capacity to work within a quasi-spherical space. It gives rise to three
rotational movements.

Figure: Jointed Arm Configuration Robot

Advantages:
1. Most flexible configuration that enables the robot arm to move in all directions
2. Large working envelope
3. Versatile configuration
Disadvantages:
1. Requires complex programming
2. Control actions are different
3. Less stable as the arm approaches maximum reach
Applications:
Painting, welding, automatic assembly, welding, pick and place operations involving lightparts,
etc.
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Industrial Applications of Robots:

The various applications of robots are grouped into three categories
Material Handling Applications:
It includes material transfer and machine loading and unloading operations. In a material transfer
application, robots are used to move materials or work parts from one location to another, usually
referred as pick and place operation. In machine loading and unloading applications, the robot is used
to load and unload parts at a production machine.
Processing Applications:

It includes performing a process on a work part, for example, welding, spray painting, grinding, dip
coating, etc. The robot is programmed to hold and manipulate a tool to perform the desiredoperation.
Assembly and Inspection:

Robots are used to assemble the various components of a product, for example picking one part and
inserting into another part with precise placement and orientation. Robots are also used in part
inspection applications, wherein the robot positions a sensor with respect to the work part and
determines whether the part is consistent with the quality specifications.

Automation in industry
Automation refers to the use of technology to perform tasks or processes without human intervention. It
involves the use of machines, software, and systems to control and manage a range of functions, from
manufacturing and production to information technology and business operations. Automation can help
increase efficiency, accuracy, and productivity, while also reducing costs and minimizing errors. It can
be applied in various industries and settings, from factories and warehouses to offices and homes.

Types of Automation
Fixed Automation
• Fixed automation, also known as hard automation, is a type of automation system that is
designed to perform a specific task or function, typically in a manufacturing or production
environment.
• Fixed automation systems are highly specialized and cannot be easily adapted to perform
othertasks.
• They are often used for high-volume, repetitive tasks that require a high degree of precision
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and accuracy, such as assembly line operations, welding, or packaging.

• Examples of fixed automation systems include conveyor belts, transfer lines, and dedicated
assembly machines.
• One of the advantages of fixed automation is that it can be very efficient and cost-effective
forlarge-scale production runs.
• However, it can be less flexible and adaptable than other types of automation, making it less
suitable for smaller-scale or custom production runs.

Some industrial examples of fixed automation include:

➢ Assembly line in automobile manufacturing

➢ Production line in food processing

➢ Automated production line in electronics manufacturing

➢ Chemical processing plant

Programmable Automation
➢ Programmable automation, also known as soft automation, is a type of automation system that
can be programmed or reprogrammed to perform different tasks or functions.

➢ Programmable automation systems are more flexible and adaptable than fixed automation
systems, making them well-suited to applications that require frequent changes or adjustments.

➢ These systems typically involve the use of computers and software to control and manage the
automation process.

➢ Examples of programmable automation systems include computer numerical control (CNC)

machines, which are used in manufacturing to control the movement of cutting tools and other
equipment, and programmable logic controllers (PLCs), which are used in a range of industries
to control and monitor various processes.

➢ One of the advantages of programmable automation is its versatility and adaptability, which
can make it more cost-effective and efficient for smaller-scale or custom production runs.

➢ However, it can also be more complex and require more specialized skills to set up and operate
than fixed automation systems.
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Some industrial examples of programmable automation include:

CNC machines in the machining industry
Automated assembly line in electronics manufacturing
Automated warehouse in the logistics industry

Flexible Manufacturing
Flexible automation is a type of automation system that combines the benefits of fixed and
programmable automation.

➢ These systems are designed to perform a range of tasks while being customizable and adaptable
to changes in production.

➢ Flexible automation systems typically involve the use of robotics, computer controls, and other
advanced technologies to enable machines to perform a wide range of tasks, such as sorting,
assembly, and packaging.

➢ These systems can be programmed and reprogrammed to accommodate changes in production

runs or product specifications, making them well-suited to applications that require a high
degree of flexibility and adaptability.
One of the advantages of flexible automation is its ability to improve efficiency and reduce
costs while still providing a high level of customization and versatility.

Basic Elements of Automation

The basic elements of automation are:

➢ Sensing Devices: These are devices that can detect changes in the environment, such as
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temperature, pressure, or motion, and convert them into electrical signals that can be processed
by a computer or control system.

➢ Control Devices: These are devices that receive input from the sensing devices and use that
information to control the operation of machines or equipment, such as motors, valves, or
actuators.

➢ Actuators: These are devices that convert electrical signals from the control system into
physical motion or force, such as hydraulic or pneumatic cylinders, or electric motors.
Power Source: This is the energy source that provides power to the machines or equipment
being controlled, such as electricity or compressed air.

➢ Control System: This is the software or hardware that controls the operation of the machines
or equipment, and processes data from the sensing devices and control devices to make
decisions about how to control the system.
These basic elements are used in various combinations to create automation systems that can perform
a wide range of tasks, from simple manufacturing processes to complex industrial control systems.

Advantages of Automation
There are several advantages of automation, including:

• Increased Efficiency: Automation can perform tasks faster and more consistently than
humans, which can lead to increased productivity and efficiency in manufacturing and other
industries.
• Improved Quality: Automation can help reduce errors and defects by ensuring that tasks are
performed consistently and accurately.
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• Reduced Labour Costs: Automation can help reduce labour costs by replacing some or all
thehuman workers required to perform a task.
• Increased Safety: Automation can help reduce the risk of workplace accidents and injuries
byeliminating the need for workers to perform dangerous tasks.
• Increased Flexibility: Automation can help increase flexibility in manufacturing and other
industries by allowing tasks to be reprogrammed or reconfigured quickly and easily.
• Improved Data Collection and Analysis: Automation can provide real-time data on the
performance of machines and equipment, which can be used to improve efficiency, reduce
downtime, and optimize production processes.

Disadvantages of Automation
While automation can provide many benefits, there are also some disadvantages to consider:

• High Initial Investment Costs: Setting up an automated system can require a significant
initialinvestment in equipment, software, and training.
• Potential Job Loss: Automation can lead to the displacement of human workers,
particularlyin industries with high levels of repetitive or routine tasks.
• Complexity And Maintenance Requirements: Automated systems can be complex and
require specialized skills and knowledge to design, program, and maintain.
• Lack Of Flexibility: Automated systems may not be as flexible as human workers,
particularlyin situations where tasks require adaptation to changing conditions.
• Dependence on Technology: Automated systems may be vulnerable to technological
malfunctions or failures, which can cause disruptions in production and require costly repairs.
• Reduced Creativity and Problem-Solving: Automation can limit the opportunities for
humanworkers to use their creativity and problem-solving skills in the workplace.

Introduction to Internet of Things

❑ The Internet of Things (IoT) describes the network of physical objects—“things”—that are
embedded with sensors, software, and other technologies for the purpose of connecting and
exchanging data with other devices and systems over the internet.
❑ Over the past few years, IoT has become one of the most important technologies of the 21st
century.
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❑ Now that we can connect everyday objects—kitchen appliances, cars, thermostats, baby
monitors—to the internet via embedded devices, seamless communication is possible between
people, processes, and things.
❑ By means of low-cost computing, the cloud, big data, analytics, and mobile technologies,
physical things can share and collect data with minimal human intervention.
❑ In this hyperconnected world, digital systems can record, monitor, and adjust each interaction
between connected things.
❑ The physical world meets the digital world—and they cooperate.

Characteristics of IoT
Characteristics are the reason behind the success of IoT. There are six main characteristics. Each
characteristic encompasses a set of capabilities that make IoT a success.

Intelligence
IoT systems are extensively liked in the market because of their intelligence. A combination of
algorithms and computer enables the system to inform change in the environment and take appropriate
actions. For example – Systems are intelligent enough to sense a sudden spike in temperature and
trigger an alarm for fire.
Connectivity
Connectivity is the main characteristic of IoT as it enables the system to send data and stay connected
to other devices. It provides system network accessibility and function collaboratively.
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Expressing
IoT is all about interacting intelligently with the outer environment and humans. Expressing enables
this interactivity. Expressing allows us to show output into the real world and input from people and the
environment.
Sensing
Sensitivity means aware of the changes around us. Sensor technologies provide us with the means to
create an experience that reflects an awareness of changes in the physical world and the people in it. It
helps in expressing.
This forms the input for the IoT system and provides a better understanding of the complex world
around us.
Energy
Everything in this world is driven by energy. IoT systems are created smart enough to synthesize
energy from the outer environment and conserve it. It is also made energy efficient to work for a longer
duration.
Security
Safety and security is the most important feature of any system. If the system is not secure to cyber
attack and illegal intervention, nobody will use it. IoT systems deal with personal data; that’s why it’s
an obligation that all safety measure should be taken care of in this system. All IoT systems are secure
enough to deal with personal data.

Applications of IoT
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Smart Home
Smart homes are the revolution in the technical world. Switching on the lights as someone walks in,
switching on AC and adjusting its temperature according to weather. Unlocks door for friends etc., is
some of the features of smart homes.
Wearables
These are the devices that have sensors embedded in them. One can wear them as a watch or specs. It
broadly covers fitness and health-related data.
Smart cities
Smart cities are another application of IoT, which includes automated transport, energy management,
environmental monitoring. Smart bins will alert municipal services that bins need to be emptied.
Some other applications are auto-driven cars, industrial internet, iot in agricultureetc.

Advantages and Disadvantages of IoT

Advantages Disadvantages

Accessing information about There is a risk of illegal access to

surroundings is easy using IoT. data as it flows on the internet.

It makes day to day life easier. IoT is very costly to implement.

IoT is connecting people to work as IoT systems are very complex; any
well as home to increase failure can affect everyone. It makes
productivity. people lazy.

The Internet of Things (IoT) is the physical devices that are connected to a network. These physical
devices are called node devices. These are embedded with sensors, software, and other technologies to
exchange data with other devices and systems over the Internet. With IoT, digital systems can record,
monitor, and adjust each interaction between connected things. Hence now we can connect everyday
objects like kitchen appliances, cars, thermostats, etc to the internet via embedded devices. This makes
communication streamlined between people, processes, and things.to understand IoT properly we need
to understand the Logical and Physical Designs of IOT in detail.
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Physical design of IoT

Now let us understand the physical design of IoT from the logical and physical design of IoT. The
Physical design of IoT deals with the individual devices connected to the IoT network and the protocols
used to create a functional IoT environment. Each IoT device can perform tasks of remote sensing,
actuating, monitoring, etc due to the IoT network they are connected to. These can also transmit
information through different types of wireless or wired connections. They can generate data, which is
used to perform analysis and perform operations for improving the system.

Now let us understand the IoT node devices and the IoT protocols.

Node Devices
Node devices are used to build a connection, process data, and provide interfaces, and storage, in an IoT
system. They generate data that can be analyzed by the IoT system and program to perform operations
and improve the system.

Now let’s understand which devices are used for which function in an IoT system.

Connectivity: Devices like USB hosts and ETHERNET provides connectivity between the devices and
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the server.
Processor: Processors like CPU and other units process the data. This is used to improve the decision
quality of an IoT system.
Audio/Video Interfaces: System interfaces like HDMI and RCA devices record audio and videos.
Input/Output interface: Devices like UART, SPI, CAN, etc give input and output signals to sensors and
actuators.
Storage Interfaces: IoT devices like SD, MMC, and SDIO generate data. Storage interfaces store those
data.
Controlling of activity: Devices like DDR and GPU control the activity of an IoT system.

IoT Protocols
IoT protocols establish communication between a node device and a server over the internet by sending
commands to an IoT device and receiving data from an IoT device. Both the server and client-side use
different types of protocols. By network layers, they are managed. Some of the network layers are the
application, transport, network, and link layers. It works as a building block for logical and physical
design of IoT.

Some of the protocols are

Application Layer protocol- Protocols in this layer define how the data is sent over the network. With
the lower layer protocols, the application interface sends these data. Examples include HTTP,
WebSocket, XMPP, MQTT, DDS, and AMQP protocols.
HTTP (HyperText Transfer Protocol)- This protocol for transmitting media documents in an application
layer by communicating between web browsers and servers.
WebSocket- it enables two-way communication between a client and a host and is mostly web browsers
use it.
Transport Layer- it controls the flow of data segments. It also handles error control and provides end-to-
end message transfer capability.
TCP (Transmission Control Protocol)- It establishes and maintains a network that can exchange data
using the internet protocol.
Some of the layers are
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Network Layer- it is used to send datagrams from the source network to the destination network. Some
examples are IPv4 and IPv6.
Link Layer- it is used to send data over the network’s physical layer and determines how the packets are
coded and signaled by the devices.
Ethernet- It is a set of protocols used in LANs that defines the physical layer and the medium access
control for LANs.
WiFi- It is a set of LAN protocols. It specifies the set of media access controls and also the physical
layer protocols that are used for implementing wireless LANs.

Logical Design of IoT

logical design of iot
It is the actual design of the IoT system. It illustrates the assembling and configuration of the
components i.e. computers, sensors, and actuators.

The logical design of IoT is composed of:

IoT functional blocks

IoT communications models
IoT communication APIs
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IoT functional blocks

The functional blocks of IoT systems provide sensing, identification, actuation, management, and
communication capabilities to the IoT ecosystem. The devices of the functional blocks handle the
communication between the server and the host. This enables monitoring of control functions, managing
the data transfer, securing the IoT system using authentication, and providing an interface for controlling
and monitoring various functions. It is the most crucial part of the logical and physical designs of IoT.

The Functional blocks of IoT are:

Device
Devices provide sensing, actuation, monitoring, and control functions to the IoT ecosystem.

Communication
Manages communication for the IoT system.

Services
Services perform the functions of device monitoring, device control, data publishing, and device
discovery.

Management
gives functions to govern the IoT system.

Security
provides security to the IoT system. It performs authentication, authorization, message and content
integrity, and data security functions.

Application
An interface where the users can control and monitor various aspects of the IoT system. It allows the
users to view the system status and analyze the processed data.
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IoT Communication Models

The communication models of IoT are used for communicating between the system and the server. The
types of IoT communication models are

Request-Response Model
In this communication model, the client sends requests to the server and the server responds to their
requests. After receiving a request, the server decides how to respond by fetching the data, retrieving
resource representation, preparing the response, and then sending the response to the client. The request-
response protocol between a client and a server is HTTP.

Publisher-Subscriber Model
Publisher-Subscriber Model
This model is made up of three entities: Publishers, Brokers, and Consumers.

Publishers- it is the source of data that sends the data to the topic.
Consumers- they subscribe to the topics.
Brokers- they accept data from publishers and send it to the consumers.
Push-Pull Model
This model is made up of data publishers, data consumers, and data queues.

Publishers- they publish the message and push it into the queue.
Consumers- they present on the other side and they pull the data out of the queue.
Queues- it helps in decoupling the messages between the producer and consumer.
Exclusive Pair
It is a bi-directional model that includes full-duplex communication between client and server. The client
sends a request and the server keeps the record of all the connections. In this model, only WebSocket-
based communication API is based.

IoT communication API

There are two types of communication APIs –

There are two types of communication APIs –

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REST-based communication APIs

REST stands for Representational State Transfer. It is a set of architectural protocols by which you can
design web services and web APIs. These web services and APIs focus on a system’s resources and how
resource states are addressed and transferred. It has a request-response communication model. Its
architectural constraints are components, connectors, and data elements. All of them are included within
a distributed hypermedia system.

Web Socket-Based Communication APIs

Web Socket API is the bi-directional, full-duplex communication model between clients and servers. It
does not require a new connection to set up for each message between clients and servers. After the
connection is set the messages can be sent and received continuously without any interruption. It is best
for IoT Applications with low latency or high throughput requirements

Difference between the physical design of IoT & logical design of IOT
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Physical Design of IOT

❑ A physical design of an IoT system refers to the individual node devices and their protocols that
are utilised to create a functional IoT ecosystem.
❑ Each node device can perform tasks such as remote sensing, actuating, monitoring, etc., by
relying on physically connected devices.
❑ It may also be capable of transmitting information through different types of wireless or wired
connections.
The things/devices in the IoT system are used for:
• Building connections
• Data processing
• Providing storage
• Providing interfaces
• Providing graphical interfaces
❑ The devices generate data, and the data is used to perform analysis and do operations for
improving the system.
❑ For instance, a moisture sensor is used to obtain the moisture data from a location, and the
system analyses it to give an output.
Logical Design of IOT
❑ A logical design for an IoT system is the actual design of how its components (computers,
sensors, and actuators) should be arranged to complete a particular function.
❑ It doesn’t go into the depth of describing how each component will be built with low-level
programming specifics.
IoT logical design includes:
IoT functional blocks:
❑ IoT systems include several functional blocks such as Devices, communication, security,
services, and application.
❑ The functional blocks provide sensing, identification, actuation, management, and
communication capability.
❑ These functional blocks consist of devices that handle the communication between the server
and the host, enable monitoring control functions, manage the data transfer, secure the IoT
system using authentication and different functions, and provide an interface for controlling and
monitoring various terms.
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IoT communications models

There are multiple kinds of models available in an Internet of Things system that is used for
communicating between the system and server, such as:
• Request-response model
• Push-pull model
• Publish-subscribe model
• Exclusive pair model
IoT communication APIs
APIs are used to communicate between the server and system in IoT. Some API’s include:
• REST-based communication APIs
• Client-server
• Stateless
• Cacheable
• Websocket based communication API

IoT Protocols
❑ The set of rules governing all direct or indirect exchange of data between computers on a
network.
❑ These rules are formulated at the application level and are used collectively to define how
devices communicate interoperably, irrespective of differences in their internal designs and
operations.
❑ IoT protocols help send commands and data between a network of devices controlled by sensors
or other physical attributes like motion, temperature, or vibration.
❑ Network protocols help achieve reliable data transfer across all layers like the application,
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transport, network, and link layer.

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