Introduction to Mechanical Engineering – BESCK204D 2022-23

INTRODUCTION TO MECHATRONICS AND ROBOTICS

Mechatronics is a multidisciplinary field that refers to the skill sets needed in the contemporary,
advanced automated manufacturing industry. At the intersection of mechanics, electronics, and
computing, mechatronics specialists create simpler, smarter systems. Mechatronics is an
essential foundation for the expected growth in automation and manufacturing. Mechatronics
deals with robotics, control systems, and electro-mechanical systems. Mechatronic
engineering harnesses the power of mechanics, electrical systems and software to create
computer-controlled ‘smart’ machines. It underpins the technology behind robotics and
autonomous systems, automated manufacturing and ‘intelligent’ microprocessor-based
technologies.

Open Loop System

A Control System which doesn’t have any feedback connected to it is called as Open
Loop System. These types of systems don’t depend upon its output i.e., in open loop systems,
output is not used as a control variable for the system and it has no effect on the input. Open loop
systems are one way signal flow systems. As these systems doesn’t contain any feedback i.e., the
output is not fed back to the input, these are also known as Non-Feedback Systems.

In an open loop system, the output can be adjusted / varied by varying the input but the output
has no effect on the input. The output of the open loop system can be determined only by its
present state input. If the output is affected due to some external noise / disturbance, the open
loop system cannot correct it.

Example - Electrical Clothes Drier

We operate the clothes drier depending upon the amount of clothes to make dry. We set a
timer in the system to do this operation, let’s say 20 mins. As it is an automatic open loop
system, the machine stops working automatically after 20 mins, irrespective of the nature of the

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 1
Introduction to Mechanical Engineering – BESCK204D 2022-23

clothes, whether they are dry or damp. The clothes drier is an open loop system, because it
doesn’t consider the condition of clothes before it stops working. The user can adjust the
operating duration of the system by setting the timer controls as per his / her requirement.
Observe the below block diagram for the open loop control system, electric drier.

Here, the electric drier system has three blocks, timer, heating elements and clothes.
Primarily, the user sets the time for drying the clothes in the timer. And the timer control works
in combination with the heating element, to produce heat and dry the clothes. As there is no
feedback about clothes, humidity, the system stops working after the preset time and it doesn’t
consider the state of clothes. Even if the clothes are dry, the system will switch off after the
allotted time. As the system has no feedback, this is also known as “non-feedback system”, in
which the output of the system depends only on the input signal and no control action of the
input signal based on the output is provided. As the open loop system doesn’t have any
knowledge of the output, it cannot correct errors itself. This is a major disadvantage of the open
loop control system. Another disadvantage is that these systems cannot handle the external
disturbances and have very poor ability to oppose the adoption of changes to external system
parameters.

Closed loop feedback system

A control system with feedback loop is called “closed loop control system”. In other
words, the control system which uses its feedback signal to generate output is called closed loop
control system. In these control systems, the input is controlled by the feedback signal from
output so that it can correct the errors occurred. Closed loop control systems are two way signal
flow systems. Feedback means, some part of output is taken and connected it to the input of the
system to maintain the stability of the control system. By providing a feedback loop, we can
convert any open loop control system into closed loop system. The feedback loop provides the

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 2
Introduction to Mechanical Engineering – BESCK204D 2022-23

automatic correction of the input signal based on the output requirement.By comparing the
generated output with the actual condition, the closed loop system maintains and achieves the
desired output. If the produced output is deviated from decided (actual) output, the closed loop
control system generates an error signal and the error signal is fed to the input of the signal. So
by adding the error signal to the input, the generated output of the next loop will be corrected. So
these are also called as automatic control systems. Closed loop systems are less prone to external
disturbances.

The block diagram of the closed loop system is shown below.

Examples

 Automatic Electric Iron –Depending on the temperature of the iron heating elements were
controlled automatically.
 Servo Voltage Stabilizer – Stabilization in voltage is achieved by the feeding the output
voltage back to the system.
 Water Level Controller– Water level in the reservoirs decides the input water into it.
 Air Conditioner –Air conditioner automatically adjusts its temperature depending on its
room temperature.
 In motor speed regulator using tachometer and/or current sensor , sensor senses the speed
and sends a feedback to the system to regulate its speed.
Automatic cloth driers- In automatic control system or closed loop feedback system, we use a
transducer at input side of the system to continuously monitor the temperature of the clothes
inside the drier. The block diagram of the electric cloth drier is shown below.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 3
Introduction to Mechanical Engineering – BESCK204D 2022-23

The temperature sensor will monitor the state of clothes, whether they are dry or wet and
compare it with the submitted input reference. If the clothes state and the desired output are not
matched then the system generates an error signal and sends it back to the input. The amplifier
produces the amplified output of the signal to the controller, so that it can adjust the heating
elements to the desired output level. So if the clothes are about to dry, then the controller
regulates and lowers the temperature or stops the heating process of the heating elements to an
extent that it doesn’t burn the clothes in the machine.

The closed loop system is capable of handling the external noise disturbances (which causes to
reduce the system efficiency) by means of the feedback signal. For example, if we open the drier,
some amount of temperature is lost and the inner temperature of the system will decrease. Then
the feedback sensor will calculate the temperature of the clothes and then it sends the error signal
to controller. So that the controller sets the required temperature in the system. This will be the
process of handling the error occurrence in clothes drier.

ROBOTICS

Robotics is an interdisciplinary branch of electronics and communication, computer

science and engineering. Robotics involves the design, construction, operation, and use
of robots. The goal of robotics is to design machines that can help and assist humans. Robotics
integrates fields of mechanical engineering, electrical engineering, information
engineering, mechatronics engineering, electronics, biomedical engineering, computer
engineering, control systems engineering, software engineering, mathematics, etc.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 4
Introduction to Mechanical Engineering – BESCK204D 2022-23

Classification based on robotics configuration

1) Rectangular Configuration:- This uses three perpendicular slides to construct the x, y, z

axes. By moving three slides relative to one another, the robot is capable of operating within a
rectangular work envelope. These are also called as Cartesian configuration robots.

2) Cylindrical Configuration:- These uses a vertical column and a slide that can be moved up
and down along the column. The robot arm is attached to the slide so that it can be moved
radially with respect to the column. By rotting the column the robot is capable of retrieving a
cylindrical work envelope.

3) Spherical Configuration:- IT uses telescopic arm that can be raised or lowered about a
horizontal pivot point. The pivot point is mounted on a rotating base and gives the robot its
vertical movement. These various joints provide the robot with the ability to move its arm within
a spherical envelope.

4) Jointed arm Configuration:- It consists of two straight components whose shoulders and
elbow joints rotate about horizontal axes corresponding to the human forearm and upper arm. Its
work envelope is of irregular shape.

5) SCARA Configuration:- It is a special version of the jointed arm robot whose shoulder and
elbow joints rotate about the vertical axes instead of horizontal. Its work envelope is cylindrical
and much larger than all other configurations, which provides a substantial rigidity in the vertical
direction for many essential tasks.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 5
Introduction to Mechanical Engineering – BESCK204D 2022-23

Applications:

Articulated robots can be used in Robots palletizing food (Bakery), Manufacturing of steel
bridges, cutting steel, Flat-glass handling, heavy duty robot with 500 kg payload, Automation in
foundry industry, heat resistant robot, metal casting, and Spot Welding.

Advantages:

• High speed
• Large working envelope
• Great in unique controller, welding and painting applications

Disadvantages:

Typically requires dedicated robot controller in addition to line master controller like PLC/PC.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 6
Introduction to Mechanical Engineering – BESCK204D 2022-23

AUTOMATION IN INDUSTRY

Automation is the creation and application of technologies to produce and deliver goods
and services with minimal human intervention. The implementation of automation technologies,
techniques and processes improve the efficiency, reliability, and/or speed of many tasks that
were previously performed by humans. Automation can be defined as "the creation and
application of technology to monitor and control the production and delivery of products and
services.”

Industrial automation is the use of technologies such as computer software and robotics
to control machinery and processes which replace human beings in performing specific
functions. The functions are primarily centered on manufacturing, quality control and material
handling processes. The advantages of automation are it will reduce the human labour required,
Consistency in quality, Fewer risks of human error, Improved health & safety and Improved
efficiency.

TYPES OF AUTOMATION
Automation systems are classed into three different types of automation:

 Fixed automation

 Programmable automation

 Flexible automation

FIXED AUTOMATION

Fixed automation is a type of automation where the process of manufacturing stays fixed by the
way it is configured, following a fixed sequence of automated processes. An example of this is
flow production, where products are continuously being made. This is often also known as “hard
automation”.
Fixed automation can be expensive to set up initially due to the equipment required, but in
return, it provides high production rates. However, it is relatively inflexible when it comes to
making changes to the product.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 7
Introduction to Mechanical Engineering – BESCK204D 2022-23

This is relatively useful for many companies who use automation to create food products of one
type and variant. It allows them to effectively produce that item and package it in bulk. Foods
that require chemical processes, for example, may use this to ensure the consistency of the
chemical processes.

Advantages:

 High levels of production

 Consistent quality in production

 Low cost per unit produced

Disadvantages:

 High initial cost

 Difficult to accommodate changes

This type of automation is best suited for: High demand and generic products that require no
change.

PROGRAMMABLE AUTOMATION
Programmable automation allows the production equipment and automation to be altered to
changing needs. This is done by controlling the automation through a program, which can be
coded in certain ways for the automation to change the sequence of automation. It’s used more

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 8
Introduction to Mechanical Engineering – BESCK204D 2022-23

commonly in low to medium levels of production, often being most suitable for batch
production. Programmable automation will often be used by factories that make different
variants of foods. This allows them to make batches, from a few dozen to potentially thousands
at a time, of one product. If the product needs changing, it simply needs to be reprogrammed.

Advantages:

 Flexibility to change products if needed

 Suitable if batch production is required

Disadvantages:

 Expensive for equipment

 Lower production levels

 Often time-consuming to change products

This type of automation is well suited for: Low/Medium demand and occasional changes in
products.

FLEXIBLE AUTOMATION
Flexible automation, also known as “soft automation”, is similar to programmable automation,
although a little more complicated. Essentially, flexible automation enables the production of
different types of products without losing time when reprogramming.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 9
Introduction to Mechanical Engineering – BESCK204D 2022-23

A flexible automation system can produce various combinations of products efficiently without
having to separate them into different batches, as required in batch production. This type of
automation tends to have medium levels of production.

Advantages:
 Flexibility of products
 No time lost with new changes to production

Disadvantages:
 High custom machinery/automation cost
 Higher cost per unit

This type of automation is best suited for: Medium demand and constant changes/large
variety in products.

BASIC ELEMENTS OF AUTOMATION

An automated system consists of three basic elements:

1. Power to accomplish the process and operate the system,

2. A program of instructions to direct the process, and

3. A control system to actuate the instructions.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 10
Introduction to Mechanical Engineering – BESCK204D 2022-23

Power to Accomplish the Automated Process

An automated system is used to operate some process, and power is required to drive the
controls. The principal source of power in automated systems is electricity. Electric power has
many advantages in automated as well as non automated processes. Electrical power can be
readily converted 10 alternative energy forms: mechanical, thermal, light, acoustic, hydraulic,
and pneumatic. Electrical energy can be stored in long life batteries for use in locations where an
external source of electrical power is not conveniently available.

Alternative power sources include fossil fuels, solar energy, water, and wind. However,
their exclusive use is rare in automated systems. In many cases when alternative power sources
are used to drive the process itself, electrical power is used for the controls that automate the
operation. For example, in casting or heat treatment, the furnace may be heated by fossil fuels.
But the control system to regulate temperature and time cycle is electrical. In other cases, the
energy from these alternative sources is converted to electric power to operate both the process
and its automation. When solar energy is used as a power source for an automated system, it is
generally converted in this way.

Program of Instructions

The actions performed by an automated process arc defined by a program of instructions

whether the manufacturing operation involves low, medium, or high production , each part or
product style made in the operation requires one or more processing steps that are unique to that
style, These processing steps are performed during a work cycle. A new part is completed during
each work cycle. The particular processing steps for the work cycle are specified in a work cycle
program. Work cycle programs are called part programs in numerical control. Other process
control applications use different names for this type of program.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 11
Introduction to Mechanical Engineering – BESCK204D 2022-23

Work Cycle Programs. In the simplest automated processes, the work cycle consists of
essentially one step, which is to maintain a single process parameter at a defined level, for
example, maintain the temperature of a furnace at a designated value for the duration of a heat
treatment cycle. (We assume that loading and unloading of the work units into and from the
furnace is performed manually and is therefore not part of the automatic cycle.) In this case,
programming simply involves sensing the temperature dial on the furnace, 'Io change the
program, the operator simply changes the temperature setting. An extension of this simple case is
when the single step process is defined by more than one process parameter, for example, a
furnace in which both temperature and atmosphere are controlled.

A control system

The control element of the automated system executes the program of instructions. The
control system causes the process to accomplish its defined function which is to carry out some
manufacturing operation. The controls in an automated system can be either closed loop 4 or
open loop. A closed loop control system, also known as a feedback control system is one in
which the output variable is compared with an input parameter, and any difference between the
two is used to drive the output into agreement with the input.

In contrast to the closed loop control system, an open loop control system operates
without the feedback loop. In this case, the controls operate without measuring the output
variable so no comparison is made between the actual value of the output and the desired input
parameter. The controller relies on an accurate model of the effect of its actuator on the process
variable. With an open loop system, there is always the risk that the actuator will not have the
intended effect on the process, and that is the disadvantage of an open loop system. Its advantage
is that it is generally simpler and less expensive than a closed loop system.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 12
Introduction to Mechanical Engineering – BESCK204D 2022-23

INTRODUCTION TO IOT

The Internet of Things, or IoT, is a network of physical devices. These devices can transfer data
to one another without human intervention. IoT devices are not limited to computers or
machinery. The Internet of Things can include anything with a sensor that is assigned a unique
identifier (UID). The primary goal of the IoT is to create self-reporting devices that can
communicate with each other (and users) in real time.

You likely use IoT devices every day. The list below outlines a few IoT devices that you may be
familiar with:
 Smart home devices. Smart devices are interactive electronics that use wireless
connections to understand user instructions. To an extent, smart home devices like
thermostats and home security systems can work autonomously to assist with daily tasks.
For example, you may program your smart thermostat to adjust automatically to a cooler
setting before you arrive home from work. Or, you may receive a security camera
notification to inform you that someone is at the door when you are not home.
 Wearable technologies. One of the most common Internet of Things examples is smart
watches. Wearable IoT technology like Fit bits and Apple Watches connect to other
devices (like your smart phone) to share data. They typically also connect to the internet to
track GPS locations.
 Personal medical devices. Personal medical devices like pacemakers are also IoT
devices. Remote medical devices can help monitor and share a patient's vital signs or
detect early signs of health issues for fast intervention.
 Autonomous vehicles. Self-driving cars and other connected vehicles rely on the internet
to share real-time information. Sensors throughout the vehicle help map its surroundings,
transmit camera footage, and respond to traffic signals.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 13
Introduction to Mechanical Engineering – BESCK204D 2022-23

CHARACTERISTICS OF IOT

1. Connectivity — Connectivity is an important requirement of the IoT infrastructure.

Things of IoT should be connected to the IoT infrastructure. Anyone, anywhere, anytime
can connect, this should be guaranteed at all times. For example, the connection between
people through internet devices likes mobile phones, and other gadgets, also a connection
between Internet devices such as routers, gateways, sensors, etc.

2. Intelligence and Identity — The extraction of knowledge from the generated data is very
important. For example, a sensor generates data, but that data will only be useful if it is
interpreted properly. Each IoT device has a unique identity. This identification is helpful in
tracking the equipment and at times for querying its status.

3. Scalability — The number of elements connected to the IoT zone is increasing day by day.
Hence, an IoT setup should be capable of handling the massive expansion. The data
generated as an outcome is enormous, and it should be handled appropriately.

4. Dynamic and Self-Adapting (Complexity) –IoT devices should dynamically adapt

themselves to changing contexts and scenarios. Assume a camera meant for surveillance. It
should be adaptable to work in different conditions and different light situations (morning,
afternoon, and night).

5. Architecture — IoT architecture cannot be homogeneous in nature. It should be hybrid,

supporting different manufacturers ‘products to function in the IoT network. IoT is not
owned by anyone engineering branch. IoT is a reality when multiple domains come
together.

6. Safety — There is a danger of the sensitive personal details of the users getting
compromised when all his/her devices are connected to the internet. This can cause a loss
to the user. Hence, data security is the major challenge. Besides, the equipment involved is
huge. IoT networks may also be at the risk. Therefore, equipment safety is also critical.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 14
Introduction to Mechanical Engineering – BESCK204D 2022-23

PHYSICAL DESIGN

Things/Devices:

Things/Devices are used to build a connection, process data, provide interfaces, provide storage,
and provide graphics interfaces in an IoT system. All these generate data in a form that can be
analyzed by an analytical system and program to perform operations and used to improve the
system. For example temperature sensor that is used to analyze the temperature generates the
data from a location and is then determined by algorithms.

 Connectivity- Devices like USB hosts and ETHERNET are used for connectivity
between the devices and the server.
 Processor- A processor like a CPU and other units are used to process the data. these data
are further used to improve the decision quality of an IoT system.
 Audio/Video Interfaces- An interface like HDMI and RCA devices is used to record
audio and videos in a system.
 Input/output interface- To give input and output signals to sensors, and actuators we use
things like UART, SPI, CAN, etc.
 Storage Interfaces- Things like SD, MMC, and SDIO are used to store the data generated
from an IoT device. Other things like DDR and GPU are used to control the activity of an
IoT system.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 15
Introduction to Mechanical Engineering – BESCK204D 2022-23

PROTOCOLS

These protocols are used to establish communication between a node device and a server
over the internet. It helps to send commands to an IoT device and receive data from
an IoT device over the internet. We use different types of protocols that are present on both the
server and client side and these protocols are managed by network layers like application,
transport, network, and link layer.

Application Layer protocol

In this layer, protocols define how the data can be sent over the network with the lower layer
protocols using the application interface. these protocols include HTTP, WebSocket, XMPP,
MQTT, DDS, and AMQP protocols.

HTTP- Hypertext transfer protocol is a protocol that presents an application layer for
transmitting media documents. it is used to communicate between web browsers and servers. it
makes a request to a server and then waits till it receives a response and in between the request
server does not keep any data between the two requests.

Web Socket- This protocol enables two-way communication between a client and a host that can
be run on an untrusted code in a controlled environment. This protocol is commonly used by web
browsers.
Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 16
Introduction to Mechanical Engineering – BESCK204D 2022-23

MQTT- It is a machine-to-machine connectivity protocol that was designed as a

publish/subscribe messaging transport. and it is used for remote locations where a small code
footprint is required.

Transport Layer

This layer is used to control the flow of data segments and handle error control. also, these layer
protocols provide end-to-end message transfer capability independent of the underlying network.

TCP- The transmission control protocol is a protocol that defines how to establish and maintain
a network that can exchange data in a proper manner using the internet protocol.

UDP- a user datagram protocol is part of an internet protocol called the connectionless protocol.
this protocol is not required to establish the connection to transfer data.

Network Layer

This layer is used to send datagrams from the source network to the destination network. we use
IPv4 and IPv6 protocols as host identification that transfers data in packets.

IPv4- This is a protocol address that is a unique and numerical label assigned to each device
connected to the network. an IP address performs two main functions host and location
addressing. IPv4 is an IP address that is 32-bit long.

IPv6- It is a successor of IPv4 that uses 128 bits for an IP address. it is developed by the IETF
task force to deal with long-anticipated problems.

Link Layer

Link-layer protocols are used to send data over the network’s physical layer. it also determines
how the packets are coded and signaled by the devices.

Ethernet- It is a set of technologies and protocols that are used primarily in LANs. It defines the
physical layer and the medium access control for wired Ethernet networks.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 17
Introduction to Mechanical Engineering – BESCK204D 2022-23

Wi-Fi- It is a set of LAN protocols and specifies the set of media access control and physical
layer protocols for implementing wireless local area networks.

LOGICAL DESIGN OF IOT

Logical design refers to the design through which the physical components are incorporated. It is
an abstract representation of the things, protocols and processes. Following are the major aspects
of logical design:

 Functional blocks
 Communication models

FUNCTIONAL BLOCKS

Functional blocks are parts of the system that interact with each other to let the services run
properly. Following are the functional blocks of the IoT ecosystem:

 Application- It is an interface that provides a control system that use by users to view
the status and analyze of system.

 Management- This functional block provides various functions that are used to
manage an IoT system.

 Services- This functional block provides some services like monitoring and controlling
a device and publishing and deleting the data and restoring the system.

 Communication- This block handles the communication between the client and the
cloud-based server and sends/receives the data using protocols.

 Security- This block is used to secure an IoT system using some functions like
authorization, data security, authentication, 2-step verification, etc.

 Device- These devices are used to provide sensing and monitoring control functions that
collect data from the outer environment.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 18
Introduction to Mechanical Engineering – BESCK204D 2022-23

COMMUNICATION MODELS

Communication models are used for making the services of IoT reach up to the end users. We
generally discuss about the following four communication model in IoT:

 Request-Response Communication model: This model is very similar to Client-Server

model. Clients request servers and as a response, servers provide them services.

 Publish Subscribe Communication Model: This model is a little elaborate and hence, is
distributed among publishers, brokers and consumers. Consumers, based on their type of
requirement, are assigned to a broker. Brokers get the data from publishers and provide to
consumers.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 19
Introduction to Mechanical Engineering – BESCK204D 2022-23

 Push Pull Communication model: In this model, Publishers push the data in a queue
and consumers are required to pull the data as and when required.

 Exclusive pair Communication model: This model is pure Client-Server model. Two
devices come in an exclusive pair and work on full duplex CS model.

Dr. Mohamed Saleem, Assoc. Prof, Dept of Mech Engg, BTI, Bangalore Page 20