Elements of Mechatronics

15ME405
Purpose & Objective
Syllabus
UNIT I - INTRODUCTION TO MECHATRONICS (8 hours)
 Introduction to Mechatronics systems, Mechatronics system
components - Measurement Systems, Control Systems, Open and
Closed Loops Systems, Sequential Controllers with examples-
Water level controller, Shaft speed control, Washing machine
control,Automatic camera and Engine management systems.
UNIT II - SENSORS AND TRANSDUCERS (10 hours)
 Introduction to sensors and transducers- classifications- Principle
and working of Resistive, capacitive, inductive and resonant
transducers- optical measurement systems-encoders, photo electric,
vision sensor, Fibre optic transducers- solid state sensors and
transducers-magnetic measurements, temperature measurements,
Chemical measurements-piezoelectric – accelerometers - ultrasonic
sensors and transducers- flow, distance, velocity measurements.
Syllabus
UNIT III - ELECTRICAL DRIVES AND CONTROLLERS
(9 hours)
 Introduction, Electromagnetic Principles, Solenoids and Relays,
Electrical drives - stepper motors, servo motors. Signal processing-
Multiplexer, operational amplifier - A/D and D/A converters –
Introduction to Data acquisition system - Proportional, Integral,
Derivative and PID controller, Micro controller.
UNIT IV - PROGRAMMABLE LOGIC CONTROLLERS
(9 hours)
 Programmable logic controller – Basic structure - Programming
units - Memory - Input - Output Modules - Mnemonics – Latching-
Timers – Internal relays - Counters - Shift Registers - Master and
Jump Controls -Programming the PLC using Ladder diagram -
Simple example of PLC application.
Syllabus
UNIT V - MECHATRONICS SYSTEM DESIGN
AND APPLICATION (9 hours)
 Mechatronics in Engineering Design, Traditional and
Mechatronics design, Applications - Pick and Place robots,
Car park barriers, Bar code reader, Wind screen wiper
wing stepper motor control. Case studies - Coin
counters, Robot walking machine.
Books
TEXT BOOKS
 Bolton.W, “Mechatronics”, Addison Wesley, 4th Edition, New Delhi,
2010.
 Bradley.D.A, Dawson.D Burd N.C.and Loader A.J, “Mechatronics”, Chapman and Hall Publications,
New York, 1993.
 Jacob Fraden, “Handbook of Modern Sensors Physics, Designs, and Applications”, Third Edition,
Springer-Verlag New York, 2004.
REFERENCES
 James Harter, “Electromechanics, Principles and Concepts and Devices”, Prentice Hall, New Delhi,
1995.
 David W. Pessen, “Industrial Automation Circuit Design and Components”, John Wiley, New York,
1990.
 Rohner.P, “Automation with Programmable Logic Controllers”, Macmillan / McGraw Hill, New York,
1996.
 Brian Morris, “Automatic Manufacturing Systems Actuators, Controls and Sensors”, McGraw Hill,
New York, 1994.
 Godfrey C. Onwubolu, “Mechatronics Principles and applications”, Butterworth-Heinemann, New
Delhi, 2006.
Introduction to
Mechatronics
Unit I – Elements of Mechatronics
What is Mechatronics?
 The word mechatronics was originated from Japan (Yasakawa
Electric Company) in the late 1960s, spread through Europe, and is
now commonly used round the globe.
 “The word, mechatronics, is composed of ‘mecha’ from mechanism
and the ‘tronics’ from electronics.
 Mechatronics solves technological problems using interdisciplinary
knowledge consisting of mechanical engineering, electronics, and
computer technology.
 In 1996, Harashima, Tomizuka, and Fukuda defined mechatronics as
being “the synergistic integration of mechanical engineering, with
electronics and intelligent computer control in the design and
manufacturing of industrial products and processes.”
What is Mechatronics?
 Bolton presented yet another definition by saying
“The term mechatronics is used for this integration
of microprocessor control system, electrical system
and mechanical system.”
 Mechatronics is the field of study concerned with the
design, selection, analysis, and control of systems that
combine mechanical elements with electronic
components, including computers and/or
microcontrollers.
 Working Definition - Mechatronics
Mechatronics is the synergistic integration of sensors, actuators, signal conditioning, power
electronics, decision and control algorithms, and computer hardware and software to
manage complexity, uncertainty, and communication in engineered systems.

Graphical Representation of Mechatronics

Examples of Mechatronics System
 Smart consumer products: home security, camera, microwave oven, toaster,
dish washer, laundry washer-dryer, climate control units, Automatic Digital
Camera etc.
 Computer disk VCR/DVD drives,ATM, etc
 Medical: implant-devices, assisted surgery, haptic, etc.
 Defense: unmanned air, ground, and underwater vehicles, smart weapons, jet
engines, etc.
 Manufacturing: NC & CNC machine tools, Rapid Prototyping, robotics, etc.
 Automotive: climate control, antilock brake, active suspension, cruise
control, air bags, engine management, safety, etc.
 Network-centric, distributed systems: distributed robotics, telerobotics,
intelligent highways, etc.
Embedded Systems
 The term embedded system is used where
microprocessors are embedded into systems and it is
this type of system we are generally concerned with in
Mechatronics.
 A microprocessor may be considered as being essentially
a collection of logic gates and memory elements that are
not wired up as individual components but whose logical
functions are implemented by means of software.
 An embedded system is a microprocessor-based
system that is designed to control a range of functions
and is not designed to be programmed by the end user in
the same way that a computer is.
Traditional and mechatronics designs
 Engineering design is a complex process involving
interactions between many skills and disciplines.
 With traditional design, the approach was for the
mechanical engineer to design the mechanical elements,
then the control engineer to come along and design the
control system. This gives what might be termed a
sequential approach to the design.
 However, the basis of the Mechatronics approach is
considered to lie in the concurrent inclusion of the
disciplines of mechanical engineering, electronics,
computer technology and control engineering in the
approach to design.
Elements of Mechatronics Systems
 Various Elements in a typical mechatronic system are
given below.
1. Actuators and Sensors
2. Signals and Conditioning
3. Digital Logic Systems
4. Software and Data Acquisition Systems
5. Computers and Display Systems
1. Sensors and Actuators
 Sensors and actuators mostly come under mechanical
systems.
 The actuators produce motion or cause some action.
 The sensors detect the state of the system, parameters,
inputs and outputs.
1. Sensors and Actuators
Actuators Sensors

The actuators produce motion The sensors detect the state

or cause some action of the system parameters,
inputs and outputs

Various actuators: Various Sensors:

Pneumatic an hydraulic Linear and rotational sensors,
actuators, electro mechanical acceleration sensors, force,
actuators, Piezoelectric, torque, pressure sensor,
Electrical Motors, i.e. D.C, A.C, temperature, proximity and
Stepper, Servo motors. light sensors.
2. Signals and Conditioning
 The mechatronic systems deal with two types of signals
and conditioning: input and output.
 The input devices receive signals from mechatronic
systems via interfacing devices and sensors, and then send
to the control circuits for conditioning and processing.
 The various input signal conditioning devices used in
mechatronic system are digital circuits, amplifiers, analog
to digital (A/D) convertors, Digital to Digital (D/D)
convertors.
2. Signals and Conditioning
 The output signals from the system are send to output /
display devices through interfacing devices.
 The various output signal conditioning devices used in
mechatronic system are digital to analog (D/A)
converters, display decoders (DD) converters, amplifiers,
power transistors, power op-amps.
3. Digital Logic Systems
 Digital Logic System control the overall system operation.
 The various digital logic systems are logic circuits,
microcontrollers, programmable logic controllers,
sequencing, and timing control, control algorithms.
4. Software and Data Acquisition System
 Data acquisition system acquires the output signals from
sensors in the form of voltage, frequency, resistance, etc.
and inputting into the microprocessor or computer.
 Software is used to control data acquisition through DAC
board.
5. Computers and Display devices
 Computers are used to store large number of data and
process further through software.
 Display devices are used to give visual feedback to the
user.
Elements of Mechatronics Systems
Mechatronic System – Block Diagram
Types of Mechatronics Systems
 Class I:
 Primarily Mechanical products with electronics
incorporated to enhance functionality.
 Eg. NC Machine tools, Variable speed drives in
manufacturing drives.
Types of Mechatronics Systems
 Class II:
 Traditional Mechanical products with significantly updated
internal devices incorporating electronics.
 The external user interface are unaltered.
 Eg. Modern Sewing Machine, Automated Manufacturing
Lines.
Types of Mechatronics Systems
 Class III:
 Systems that retain the functionality of traditional
mechanical systems but internal mechanisms are replaced
by electronics.
 Eg. Digital watch, automatic camera.
Types of Mechatronics Systems
 Class IV:
 Products designed with mechanical and electronic
technologies through synergistic integration.
 Eg. Photo copiers, intelligent washers and dryers, rice
cookers, automatic ovens.
Advantages of Mechatronics system
 Cost effective and good quality products

 High degree of flexibility to modify or redesign

 Very good performance characteristics

 Wide area of application

 Greater productivity in case of manufacturing organization

 Possibility of remote controlling as well as centralized

monitoring and control

 Greater extend of machine utilization

Disadvantages of Mechatronics system
 High Initial cost

 Multi-disciplinary engineering background required to

design and implementation

 Need of highly trained workers

 Complexity in identification an correction of problems in

the system
System
 The word system in mechatronics refers to a group of
physical components connected or related in such a
manner as to form as entire unit for performing the
specified task.
 A system can be thought of as a box or a block diagram
which has an input and an output and where we are
concerned not with what goes on inside the box but only
the relationship between the input and the output.
System

Input System Output

Input Electric Output

Electric Power Heat
Heater

Input Output Rotation

Electric Power Motor
Measurement System
 A measurement system involves the precise measurement
and display/recording of physical, chemical, mechanical,
electrical or optical parameters.
 It provides means of describing natural phenomena in
quantitative terms.
 Measurement system provides the input to the control
system.
 It has its input the quantity being measured and its output
the value of that quantity.
 For example, a temperature measurement system, i.e. a
thermometer, has an input of temperature and an output
of a number on a scale
Elements of measurement system
 A generalized measurement system comprises of the
following:
1. Sensor/Transducer
2. Signal Processor
3. Display or Recording device
Elements of measurement system
1. Sensor
 A sensor which responds to the quantity being
measured by giving as its output a signal which is
related to the quantity.
 For example, a thermocouple is a temperature sensor.
The input to the sensor is a temperature and the output
is an e.m.f. which is related to the temperature value.
2. Signal Processor / Conditioner
 A signal conditioner takes the signal from the
sensor and manipulates it into a condition which is
suitable either for display, or, in the case of a control
system, for use to exercise control.
 Thus, for example, the output from a thermocouple is a
rather small e.m.f. and might be fed through an amplifier
to obtain a bigger signal. The amplifier is the signal
conditioner.
3. Display Device
 A display system where the output from the signal
conditioner is displayed.
 This might, for example, be a pointer moving across a
scale or a digital readout.
Example of Measurement System
Modeling System
 The term modelling is used when we represent the
behaviour of a real system by mathematical equations,
such equations representing the relationship between the
inputs and outputs from the system.
 For example, a spring can be considered as a system to
have an input of a force F and an output of an extension x.
The equation used to model the relationship between the
input and output might be F= kx , where k is a constant.
Modeling System
Modeling System
Connected System
 In other than the simplest system, it is generally useful to
consider it as a series of interconnected blocks, each such
block having a specific function.
 We then have the output from one block becoming the
input to the next block in the system.
 In drawing a system in this way, it is necessary to
recognise that lines drawn to connect boxes indicate a
flow of information in the direction indicated by an arrow
and not necessarily physical connections.
Connected System
Control System
 A control system in mechatronics refers to a group of
physical components connected or related in such a
manner as to command direct or regulate itself or
another system.
Control System
 A control system can be thought of as a system which
can be used to:
 Control some variable to some particular value, e.g. a central
heating system where the temperature is controlled to a
particular value.
 Control the sequence of events, e.g. a washing machine where
when the dials are set to, say, ‘white’ and the machine is then
controlled to a particular washing cycle, i.e. sequence of events,
appropriate to that type of clothing.
 Control whether an event occurs or not, e.g. a safety lock on a
machine where it cannot be operated until a guard is in
position.
Key Terms and Elements of the Control
System
 Reference variable or input: Stimulus or excitation
applied to a control system from an external source,
usually in order to produce a specified response from the
system.
 Output:The actual response obtained from the system.
 Feedback: That portion of the output of a system that is
returned to modify the input.
 Error: Difference between the input stimulus and output
response.
 Disturbance: Any signal other than the reference which
affects the system performance.
Key Terms and Elements of the Control
System
 Actuating Signal: The difference between the feedback
signal and reference signal
 Control and Feed Forward Elements: Those
components directly connected between the controlled
output and the referenced input.
 Controlled output: The variable that the system seeks
to guide or regulate.
 Feedback elements: Those components required to
establish the desired feedback signal by sensing the
controlled output.
Feedback
Examples of Control System
 Cooling Level Control System

Required Temperature Industrial Cooler Temperature of the unit

Input Control System Output

Feedback of temperature
of the unit present
Examples of Control System
 Idle speed control system of an automobile
 Print wheel control system of a printer
 Temperature control of an electric furnace or oven
 Sun tracking control of a solar controller
 Aircraft rudder control system
 Gun or missile director
 Missile guidance system
 Laser guided projects
 Automatic pilot
Classification of Control Systems
 Control Systems are classified as open and closed loop
control systems.
1. Open loop control systems
2. Closed loop or feedback loop control systems
Open Loop Control System
 Open Loop Systems are systems in which the output of
the system is not used to control the system.
 Open loop is essentially a feed forward system.

Input
Output or response
or stimulus System
or controlled variable
or control signal
Elements of open loop control system
 The basic elements of open loop control system are:
1. Amplifier and
2. Controller

Controlled
Reference Amplifier Controller Output
Input
Example of an open loop control system
Advantages and Disadvantages of open loop
control system
Advantages:
 Simple and cost effective construction
 Easy maintenance
 Good stability
 Good reliability
 Quicker response
 No calibration problem
 Convenient
Advantages and Disadvantages of open loop
control system
Disadvantages:
 Less accurate
 Slow because of manual control
 Optimization in control not possible
 System is affected by internal and external disturbances
Closed Loop Control System
 Closed loop system uses feedback loop to control the
operation of the system.
 In closed loop or feedback control the controller notices
what actually takes place at the output end and drives the
plant in such a way as to obtain the desired output.
Elements of Closed Loop Control System
 The essential elements are:
1. Comparison element
2. Control element
3. Correction element
4. Process elements
5. Measurement elements
Elements of Closed Loop Control System
1. Comparison Element
 This compares the required or reference value of the
variable condition being controlled with the measured
value of what is being achieved and produces an error
signal.
 It can be regarded as adding the reference signal, which is
positive, to the measured value signal, which is negative in
this case:
 error signal = reference value signal - measured value
signal
2. Control Element
 This decides what action to take when it receives an
error signal.
 It may be, for example, a signal to operate a switch or
open a valve.
3. Correction Element
 The correction element produces a change in the process
to correct or change the controlled condition.
4. Process Element
 The process is what is being controlled.
5. Measurement Element
 The measurement element produces a signal related to
the variable condition of the process that is being
controlled.
Example of Closed loop control system
Heating a room: a closed-loop system, the various elements are:
 Controlled variable – the room temperature
 Reference value – the required room temperature
 Comparison element – the person comparing the measured
value with the required value of temperature
 Error signal – the difference between the measured and
required temperatures
 Control unit – the person
 Correction unit – the switch on the fire
 Process – the heating by the fire
 Measuring device – a thermometer
Example of Closed loop control system
 Heating a room: a closed-loop system
Advantages and Disadvantages of open loop
control system
Advantages:
 Provides much more stability
 Better repeatability
 Overcome temperature and hysteresis effects
 Perform task faster than open loop
 Good reliability
 Optimization in control is possible
Advantages and Disadvantages of open loop
control system
Disadvantages:
 Complicated in construction
 Cost is higher
Open Loop Vs Closed Loop System

SI.No. Open loop system Closed loop system

1 Not using feedback Feedback using

2 Less accurate More accurate

3 Simple in construction Complicated in construction

4 Optimisation in control is not Optimisation in control is possible

possible
5 Easy maintenance & cost is less Difficult to maintain & cost is more

6 Eg. CD deck, Digital thermometer Eg. Automatic water level, washing

machine
Automated Control System
 An automatic control system is a preset closed loop
control system that requires no operator action.
 Most of the closed loop control system are automatic in
nature
Automatic control of water level/tank level
Automatic control of water level/tank level
Automatic control of water level/tank level
It is a closed-loop control system with the elements being:
 Controlled variable – water level in tank
 Reference value – initial setting of the float and lever position
 Comparison element – the lever
 Error signal – the difference between the actual and initial
settings of the lever positions
 Control unit – the pivoted lever
 Correction unit – the flap opening or closing the water supply
 Process – the water level in the tank
 Measuring device – the floating ball and lever
Shaft speed control
Shaft speed control
Shaft speed control
 Controlled variable – speed of rotation of shaft
 Reference value – setting of slider on potentiometer
 Comparison element – differential amplifier
 Error signal – the difference between the output from the
potentiometer and that from the tachogenerator system
 Control unit – the differential amplifier
 Correction unit – the motor
 Process – the rotating shaft
 Measuring device – the tachogenerator
Analogue and digital control systems
 Analogue systems are ones where all the signals
are continuous functions of time and it is the size of
the signal which is a measure of the variable.
 Digital signals can be considered to be a sequence
of on/off signals, the value of the variable being
represented by the sequence of on/off pulses.
Analogue and digital control systems
 Analogue-to-digital converter (ADC) and digital-to-
analogue converter (DAC) elements are included in the
loop in order that the microprocessor system can be
supplied with digital signals from analogue measurement
systems and its output of digital signals can be converted
to analogue form to operate the correction units.
 The microprocessor system combines the function of
comparison and controller.
Digital closed-loop control system
Digital closed-loop control system
Sequential controllers
 The term sequential control is used when control is
such that actions are strictly ordered in a time- or
event-driven sequence.
 Such control could be obtained by an electric circuit with
sets of relays or cam-operated switches which are wired
up in such a way as to give the required sequence.
 Such hard-wired circuits are now more likely to have
been replaced by a microprocessor-controlled system,
with the sequencing being controlled by means of a
software program.
Automatic Washing Machine System – Cam
Operated Switch
Automatic Washing Machine System
Programmable logic controller
 In many simple systems there might be just an embedded
microcontroller, this being a microprocessor with
memory all integrated on one chip, which has been
specifically programmed for the task concerned.
 A more adaptable form is the programmable logic
controller (PLC).
 This is a microprocessor based controller which uses
programmable memory to store instructions and to
implement functions such as logic, sequence, timing
counting and arithmetic to control events and can be
readily reprogrammed for different tasks
Programmable logic controller
 Programmable logic controllers are widely used in
industry where on/off control is required.
 For example, they might be used in process control
where a tank of liquid is to be filled and then heated to a
specific temperature before being emptied.
The digital camera and autofocus
The digital camera and autofocus

Feed Back
Device
The Automatic Camera
Transfer Function
 The relationship defined between the output and input in
terms of a transfer function, this stating relationship
between the laplace transform of the output and the
laplace transform of the input.
Transfer Function
Laplace Transforms - Inputs
Laplace Transform
Laplace Transform
Laplace Transform
Laplace Transform
First Order Systems
First Order System with Step input
First Order System - Example
Second Order System
Second Order System
Second Order System with step input
System in Series
System with Feedback Loops
System with Feedback Loops
References
 Bolton.W,“Mechatronics”, Addison Wesley, 4th Edition, New Delhi, 2010.
 Bradley.D.A, Dawson.D Burd N.C.and Loader A.J, “Mechatronics”, Chapman and Hall
Publications, NewYork, 1993.
 Jacob Fraden, “Handbook of Modern Sensors Physics, Designs, and Applications”, Third
Edition, Springer-Verlag NewYork, 2004.
 James Harter, “Electromechanics, Principles and Concepts and Devices”, Prentice Hall, New
Delhi, 1995.
 David W. Pessen, “Industrial Automation Circuit Design and Components”, John Wiley, New
York, 1990.
 Rohner.P, “Automation with Programmable Logic Controllers”, Macmillan / McGraw Hill,
NewYork, 1996.
 Brian Morris, “Automatic Manufacturing Systems Actuators, Controls and Sensors”,
McGraw Hill, New York, 1994.
 Godfrey C. Onwubolu, “Mechatronics Principles and applications”, Butterworth-Heinemann,
New Delhi, 2006.
 Vijayaraghavan G.K, Rekha R.L, Shylaja R., “Mechatonics”, A.R.S. Publications, Chennai,
2012.