Introduction to Mechatronics

MET402
MECHATRONICS
AS PER KTU-2019 SYLLABUS
SUKESH O P
Assistant Professor
Dept. of Mechanical Engg.
Jyothi Engineering College,
sukeshop@jecc.ac.in/9633103837
4/20/2023 SUKESH O P/ APME/MET402- MR-2023 1
MODULE-1
1.1 Introduction

GOOGLE CLASSROOM CODE

MET402 MECHATRONICS

SYLLABUS
Introduction to Mechatronics, sensors, Actuators,
Micro Electro Mechanical Systems (MEMS),
Mechatronics in Computer Numerical Control
(CNC) machines, Mechatronics in Robotics-
(CNC) machines, Mechatronics in Robotics-
Electrical drives, Force and tactile sensors, Image
processing techniques, Case studies of
Mechatronics systems.

TEXT BOOK
1. Bolton W., Mechatronics: Electronic Control Systems in Mechanical and
Electrical Engineering, Person Education Limited, New Delhi, 2007
2. Ramachandran K. P., G. K. Vijayaraghavan, M. S. Balasundaram,
2. Ramachandran K. P., G. K. Vijayaraghavan, M. S. Balasundaram,
Mechatronics: Integrated Mechanical Electronic Systems, Wiley India Pvt.
Ltd., New Delhi, 2008.
3. Saeed B. Niku, Introduction to Robotics: Analysis, Systems, Applications,
Person Education, Inc., New Delhi, 2006.
Don’t use Airwalk Publications- Mechatronics Textbook if you need to score
passmark in this subject

MODULE-I
Introduction to Mechatronics: Structure of Mechatronics system.
Sensors - Characteristics - Temperature, flow, pressure sensors.
Displacement, position and proximity sensing by magnetic,
optical, ultrasonic, inductive, capacitive and eddy current
methods. Encoders: incremental and absolute, gray coded
optical, ultrasonic, inductive, capacitive and eddy current
methods. Encoders: incremental and absolute, gray coded
encoder. Resolvers and synchros. Piezoelectric sensors. Acoustic
Emission sensors. Principle and types of vibration sensors.
Actuators: Mechanical actuators, Electrical actuators, Hydraulic
and Pneumatic actuators

MODULE-II
Directional control valves, pressure control valves, process
control valves. Rotary actuators. Development of simple
hydraulic and pneumatic circuits using standard Symbols.
Micro Electro Mechanical Systems (MEMS): Fabrication:
Deposition, Lithography, Micromachining methods for MEMS,
Micro Electro Mechanical Systems (MEMS): Fabrication:
Deposition, Lithography, Micromachining methods for MEMS,
Deep Reactive Ion Etching (DRIE) and LIGA processes.
Principle, fabrication and working of MEMS based pressure
sensor, accelerometer and gyroscope.

MODULE-III
Mechatronics in Computer Numerical Control (CNC)
machines: Design of modern CNC machines -
Mechatronics elements - Machine structure: guide
ways, drives. Bearings: anti friction bearings,
hydrostatic bearing and hydrodynamic bearing.
hydrostatic bearing and hydrodynamic bearing.
Re-circulating ball screws, pre-loading methods.
Re-circulating roller screws. Measuring system for
NC machines - direct and indirect measuring
system. System modeling - Mathematical models
and basic building blocks of general mechanical,
electrical, fluid and thermal systems.

MODULE-IV
Typical elements of open and closed loop control
systems. Adaptive controllers for machine tools.
Programmable Logic Controllers (PLC) –Basic structure,
input/ output processing. Programming: Timers, Internal
Relays, Counters and Shift registers. Development of
input/ output processing. Programming: Timers, Internal
Relays, Counters and Shift registers. Development of
simple ladder programs for specific purposes.
Case studies of Mechatronics systems: Automatic
camera, bar code reader, pick and place robot,
automatic car park barrier system, automobile engine
management system.

MODULE V
Mechatronics in Robotics-Electrical drives: DC, AC,
brushless, servo and stepper motors. Harmonic drive.
Force and tactile sensors. Range finders: ultrasonic
and light-based range finders Robotic vision system -
and light-based range finders Robotic vision system -
Image acquisition: Vidicon, charge coupled device
(CCD) and charge injection device (CID) cameras.
Image processing techniques: histogram processing:
sliding, stretching, equalization and thresholding.

MODULE-I
Introduction to Mechatronics: Structure of
Mechatronics system. Sensors - Characteristics -
Temperature, flow, pressure sensors. Displacement,
position and proximity sensing by magnetic, optical,
ultrasonic, inductive, capacitive and eddy current
ultrasonic, inductive, capacitive and eddy current
methods. Encoders: incremental and absolute, gray
coded encoder. Resolvers and synchros. Piezoelectric
sensors. Acoustic Emission sensors. Principle and types
of vibration sensors. Actuators: Mechanical actuators,
Electrical actuators, Hydraulic and Pneumatic
actuators

MODULE-1
Introduction to Mechatronics : Structure of Mechatronics system.

REVOLUTION
What are the revolutions ……….

DIFFERENCE B/W AUTOMATION & MECHATRONICS
Automation and Robotics Engineering is the use of
control systems and information technologies to reduce
reduce the
the
need
need for
for human
human work
work in the production of goods and
services Mechatronics is considered to be equal parts
mechanical engineering, electrical engineering, and
mechanical engineering, electrical engineering, and
software programming/engineering.
Mechatronics specialists often work on projects related to
industrial automation but tackle other projects too. And
while mechatronics is an umbrella term covering many
disciplines, industrial automation is more tightly focused.
It seeks to let machines perform tasks that began as solely
manual duties.

INTRODUCTION TO MECHATRONICS
The term “Mechatronics" was first assigned by
Mr. Tetsuro Mori, a senior engineer of the
Japanese company Yaskawa, in 1969.
The word "mechatronics" was registered
as trademark by the company in Japan with the
registration number of "46-32714" in 1971.

MECHATRONICS
Mechatronics is a multidisciplinary field of science that
includes a combination of mechanical engineering,
electronics, computer engineering, telecommunications
engineering, systems engineering and control engineering.
engineering, systems engineering and control engineering.
It specifically refers to multidisciplinary approach to
product and Manufacturing system design.

MECHATRONICS - Definition
Mechatronics basically refers to mechanical electronic
systems and normally described as a synergistic
integration of mechanical engineering, electronics and
intelligent computer control in design and manufacture of
products and processes.
Synergistic – means various parts
products and processes.
In other words : synergistic integration of mechanical
engineering, electronic engineering, computer technology
and control engineering in development of
electromechanical products, through an integrated design
approach.

MECHATRONICS

MODEL OF A TYPICAL MECHATRONIC SYSTEM

MODULES OF A MECHATRONIC SYSTEM
1. Sensing
 I. Sensors
 II. Signal Conditioning
 III. Analog-to-Digital and Digital-to-Analog Conversion
2. Control
2. Control
 I. Open Loop and Closed Loop Control
3. Action
 I. Drive Circuits
 II. Actuators
 III. Motors

MODULES IN MECHATRONIC SYSTEM
 IM – Interface Module
 ASM – Assembly Module
 PM- Processor Module.
 EM- Environment Module
 EM- Environment Module
 CM- Communication Module
 MM- Measurement Module
 AM- Actuation Module
 SM- Software Module

Environment
Environment module
module
This module is concerned with the parameter like forces,
temperature, speed and their effect on boundary of the system. This
also deals with the dynamics and existence of the system and the
also deals with the dynamics and existence of the system and the
function.
Assembly
Assembly Module
Module
Manufacturing mechanical and structural realization, part and system
integration are the activities in this module. Input information is received
from actuation module and output is given to measurement module.

Measurement Module
Measurement Module
Sensors and micro devices, transducers are the some
components of this module, which supply information output to
components of this module, which supply information output to
communication module. Gathers information about system status.
Actuation Module
Actuation Module
Hydraulic , pneumatic and electric actuators, piezo-electric
devices, microcontrollers are the systems identified few in this module.
This module recieves information from the communication module for
execution.

Communication
Communication Module
Module
this is concerned with transmission of information b/w modules within
the system. The input and output information's reveal the nature of signal and
the system. The input and output information's reveal the nature of signal and
distance over which it has to be transmitted and operating environment. This
module mainly interacts with the processor module.
Processor
Processor Module
Module
This is formed by micro processors, embedded and electronic circuits. This
extracts information from communication module about measurement
parameters, demand settings system parameters to be processed. This module
interacts with interface module and the software module for information
processing.

Software
Software Module
Module
this module contains instructions for opening, defined algorithms,
operation control programs of processor module. The nature and forms of
operation control programs of processor module. The nature and forms of
instruction are linked to associate and interact with processor module.
Interface
Interface Module
Module
Between various levels in the system, are interfaced for transfer of
information with interaction with processor module and the system representing
the world. This provides man-machine interface for user information. The
information is classified by nature od i/p x o/p.

COMPONENTS OF A MECHATRONICS SYSTEM /
STRUCTURE OF A MECHATRONICS SYSTEM

COMPONENTS OF A MECHATRONICS SYSTEM
1. Actuators: Produce motion or cause some action. DC motor, Stepper motors,
servomotors, hydraulics, pneumatics
2. Sensors: detect the state of the system parameters, inputs and outputs. Switches,
Potentiometer, Strain gauge, Thermocouple, digital encoder
3. Input signal conditioning and interfacing: provide connection b/w the control
3. Input signal conditioning and interfacing: provide connection b/w the control
circuits and the I/P Discrete circuits, Amplifiers, Filters, A/D,D/D
4. Digital control architectures: Control the system. Logic circuits, microcontroller,
PLC
5. Output signal conditioning and interfacing : provide connection b/w the control
circuits and the O/P
D/A, D/D, Amplifiers, Power transisters.
6. Graphical Display : Provide visual feedback to users.LEDs, Digital displays,
LCD, CRT

LEVELS OF MECHATRONICS SYSTEM
1.
1. Primary
Primary Level
Level : Integrates electrical signaling with mechanical
action at the basic control level. e.g.: fluid
fluid valves
valves and
and relay
relay
switches
switches.
.
2.
2. Secondary
Secondary Level
Level : Integrates microelectronics into electrically
controlled devices. e
e.
.g
g.
. cassette
cassette tape
tape player
player.
.
SUKESH
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APME/MET402-
MR-2023
controlled devices. e
e.
.g
g.
. cassette
cassette tape
tape player
player.
.
3.
3. Tertiary
Tertiary Level
Level : Incorporates advanced control strategy using
microelectronics, microprocessors and other application
specific integrated circuits. e
e.
.g
g.
. microprocessor
microprocessor based
based
electrical
electrical motor
motor used
used for
for actuation
actuation purpose
purpose in
in robots
robots.
. A large
factory system that is also a distributed system but which links
a number of major subsystems such as machining centers,
robots for part handling, automated inspection stations etc,
SUKESH
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LEVELS OF MECHATRONICS SYSTEM
4.
4. Quaternary
Quaternary Level
Level : This level attempts to improve smartness
a step ahead by introducing intelligence ( artificial neural
network and fuzzy logic ) and fault detection and isolation (
F.D.I.) capability into the system. A system that incorporates
intelligent control or artificial intelligence, for ex: humanoid
robot.
SUKESH
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intelligent control or artificial intelligence, for ex: humanoid
robot.
SUKESH
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APME/ME407

INTRODUCTION TO MECHATRONICS SYSTEMS
ADVANTAGES OF MECHATRONICS SYSTEMS
 Cost effective and Very good quality.
 High degree of flexibility.
 Greater productivity.
 Higher quantity and producing reliability.
 Greater extent of machine utilization.
 Maintenance cost is less.
 Machining of complex designs can be done.

 High initial cost.
 Skilled worker is required.
 Fault detection s complex.
DISADVANTAGES OF MECHATRONICS SYSTEMS
 Complicated design and system

 High quality product.
 High reliability and Safety.
 Low cost.
FEATURES/CHARACTERISTICS OF MECHATRONICS
SYSTEMS
 Low cost.
 Portable.
 Produced quickly.
 Serviceability, maintainability and upgradability.

 Automotives.
 Flexible manufacturing systems(FMS).
 Measurement systems.
SUKESH
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APPLICATIONS OF MECHATRONICS SYSTEMS
 Cd/DVD and setup boxes.
 Robots employed in inspection and welding operations.
 Scanners/photocopier/fax .
 Automatic washing machines.
 Air conditioners, elevator controls.
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APME/MET402

 Better design of products.
 Better process planning.
 Reliable and quality oriented manufacturing.
SCOPE OF MECHATRONICS SYSTEMS
 Reliable and quality oriented manufacturing.
 Intelligent process and production control.
 Manufacturing of complex parts.
 More Accurate and more precision of jobs.

SYSTEM
SYSTEM
System is a group of physical components combined to
perform a specific function. All mechatronics devices consist of
systems. A system can be considered as a box that has an
input and an output.
A control system can be considered as a device that is used to
control the output of the system to a desired value.
Ex: domestic air-conditioning

SYSTEM
Electric Generator
Output
Input
Mechanical rotation Electric power

MEASUREMENT SYSTEMS
MEASUREMENT SYSTEMS
Digital Tachometer
Output
Input
Rotation of a
shaft
Number on the
LED display
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shaft LED display
SUKESH
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INTRODUCTION TO MEASUREMENT SYSTEMS
INTRODUCTION TO MEASUREMENT SYSTEMS
Elements of measuring system
1. Transducer : is a sensing that converts a physical input into
output, usually voltage.
2. Signal processor: performs filtering and amplification
2. Signal processor: performs filtering and amplification
functions.
3. Recorder: records or displays the output of signal processor.
Transducer
Signal
Processor
Recorder

FUNCTIONS
FUNCTIONS OF
OF INSTRUMENTS
INSTRUMENTS AND
AND MEASUREMENT
MEASUREMENT SYSTEMS
SYSTEMS
1.
1. Indicating
Indicating function
function:
: Examples :- (1) A pressure gauge is used
for indicating pressure. (2) The deflection of a pointer of a
speedometer indicates the speed of the automotive at that
moment.
2.
2. Recording
Recording function
function: Examples :- (1) A potentiometer type of
2.
2. Recording
Recording function
function: Examples :- (1) A potentiometer type of
recorder used for monitoring temperature records the
instantaneous values of temperatures on a strip chart recorder.
3.
3. Controlling
Controlling function
function:
: This is one of the most important functions
specially in the field of industrial control processes.

APPLICATIONS OF MEASUREMENT SYSTEMS
1
1.
. Monitoring
Monitoring of
of processes
processes and
and operations
operations:
:
Example : (1) A voltmeter indicates the value of current or voltage being
monitored(measured) at a particular instant. (2)Water and electric energy
meters.
2
2.
. Control
Control of
of processes
processes and
and operation
operation:
:
Example : (1) Typical refrigeration system which employs a thermostatic
control.
(2) A temperature measuring device senses the room temperature thus
providing the information necessary for proper functioning of the control
system.

3. Experimental engineering analysis:
3. Experimental engineering analysis:
(1) Determination of system parameters, variables and performance
indices.
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(2) Testing the validity of theoretical predictions.
(3) Solutions of mathematical relationships with the help of analogies.
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APME/MET402

MEASUREMENT SYSTEM PERFORMANCE
MEASUREMENT SYSTEM PERFORMANCE
1. Static characteristics
a. Accuracy b. sensitivity
c. Reproducibility d. Static error.
2. Dynamic characteristics
a. speed of response b. Measuring lag.
c. Fidelity d. Dynamic error

CONTROL SYSTEMS
CONTROL SYSTEMS
A control system is an arrangement of physical components
connected or related in such a manner as to command, direct or
regulate itself or another system.
The basic functions of control systems are:
The basic functions of control systems are:
- to minimize the error b/w the actual and the desired
output.
- to minimize the time response to load changes in the
system.

REQUIREMENTS OF A CONTROL SYSTEM
REQUIREMENTS OF A CONTROL SYSTEM
1. Stability : for any change in the input signal, the output of
the system reads or makes its response at reasonable
value.
2. Accuracy : the closeness of the measured value to the true
2. Accuracy : the closeness of the measured value to the true
value is known as accuracy.
3. Response : the quickness with which an instrument responds
to a change in the output signal is known us response.

EXAMPLES OF CONTROL SYSTEM APPLICATIONS
EXAMPLES OF CONTROL SYSTEM APPLICATIONS
1. Steering control of automobile.
2. Printwheel control system.
3. Industrial sewing machines.
3. Industrial sewing machines.
4. Sun-tracking control of solar collectors.
5. Speed control systems.
6. Temperature control of an electric furnace.

ELEMENTS OF A CONTROL SYSTEM
1. Control variable
The quantity or condition of the controlled system which
can be directly measured and controlled is called Controlled
variable.
variable.
2. Indirectly controlled variable
The quantity or condition related to controlled variable,
but cannot be directly measured is called Indirectly controlled
variable

3
3.
. Command
Command :
: The input which can be independently varied is
called Command.
4
4.
. Reference
Reference input
input:
: A standard signal used for comparison in the
close-loop system.
close-loop system.
5
5.
. Actuating
Actuating signal
signal:
: The difference between the feedback signal
is called Actuating signal.
6
6.
. Disturbance
Disturbance:
: Any signal other than the reference which affects
the system performance is called disturbance.
7
7.
. System
System error
error:
: The difference between the actual value and
ideal value is called System error.

TYPES OF CONTROL SYSTEMS
TYPES OF CONTROL SYSTEMS
Open-loop control systems
or
Non-feedback control systems.
Closed-loop control systems
or
Feedback control systems.

OPEN
OPEN-
-LOOP CONTROL SYSTEMS
LOOP CONTROL SYSTEMS

ADVANTAGES AND DISADVANTAGES OF OLS
ADVANTAGES AND DISADVANTAGES OF OLS
ADV:
Simple construction.
Easy maintenance.
Less cost.
Has better reliability and stability.
LIMITATIONS
Presence of non-linearities causes malfunctioning.
The error cannot be corrected.
The control action depends upon input command.
Its not suitable for rough works.

CLOSED
CLOSED-
-LOOP CONTROL SYSTEMS
LOOP CONTROL SYSTEMS

ADVANTAGES AND DISADVANTAGES OF CLS
ADV
More accurate
Control action basically depends upon feedback.
SUKESH O P/ APME/MET402- MR-2023
Control action basically depends upon feedback.
Change in system component is automaticaly taken care of.
DISADV:
The system is complicated and expensive.
The system may become unstable.

Some examples:
Washing machine
The electric switch
Feedforward
control system
Microwave oven
Air conditioner
Liquid level control
Feedback
control system

Open-loop
1. Less accurate
2. Generally build easily
3. Stability can be ensured.
4. The control adjustment depends
Closed-loop
1. More accurate.
2. Generally complicated and
costly
3. May become unstable at times.
upon human judgment and
estimate.
5. Any change is system
component cannot be taken
care of automatically.
3. May become unstable at times.
on output and feedback
element.
5. Change in system component is
automatically taken care of.

FEED BACK PRINCIPLE
FEED BACK PRINCIPLE
The required level of control in open-loop systems depends only on
human judgment. So, the performance of a control system can be
improved by upgrading the skill of the operator and the nature of the
measurement. Only with experience is one able to predict the results
obtained.
obtained.
Ex: Ironbox

BASIC ELEMENTS OF A FEEDBACK SYSTEM
1
1.
. Forward
Forward path
path:
: The forward path consist of
1.
1. Error
Error-
-detecting
detecting device
device:
: it is a device that receives the
output signal and compares it with a standard value. It
also gives the command o/p signal at each &every
also gives the command o/p signal at each &every
instant.
2.
2. Amplifier
Amplifier :
: it amplifies the o/p signal to a suitable/
required scale.
3.
3. Compensating
Compensating network
network:
: it improves the overall
performance of the system.

2
2.
. Feedback
Feedback system
system:
: This is the path that sends the
information about the o/p signal at each and every instant
to the error-detecting device.

CLASSIFICATION OF FEEDBACK CONTROL SYSTEMS
1. Regulatory systems.
2. Follow-up system.
3. Servo-mechanism systems.
SUKESH O P/ APME/MET402- MR-2023
3. Servo-mechanism systems.
4. Continuous data feedback systems.
5. Sampled or discrete data control systems.
4/20/2023 62

1
1.
. Regulatory
Regulatory systems
systems:
: this feedback control system is used
when the input signal is constant, for ex: Refrigerator, Iron box
2
2.
. Follow
Follow-
-up
up system
system:
: this feedback control system is used when
the input signal changes at each and every instant and where
the input signal changes at each and every instant and where
the output follows the input signal closely, Ex: Cam and follower
mechanism
3
3.
. Servo
Servo mechanism
mechanism system
system:
: This feedback control system is
used where the mechanical quantity output with time
derivatives is used.

4
4.
. Continuous
Continuous data
data feedback
feedback systems
systems:
: This feedback control
system is used where the input signal has functions of the
continuous time variable.
Ex: Potentiometers.
SUKESH
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APME/MET402-
MR-2023
Ex: Potentiometers.
5
5.
. Sampled
Sampled or
or discrete
discrete data
data control
control systems
systems:
: This feedback
control system is mainly used in input signals that have pulses
or have numerical codes.
Ex: A/D converter and Digital to Analog(D/A) converter.
SUKESH
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APME/MET402

13-2-23, 4TH HOUR
Absentees: 3,7,13,19,32,33,37,49,57,59,63,64,66,
14-02-2023, 2nd hour
14-02-2023, 2 hour
Absentees : 7,13,18,30,40,53,64,66,
4th hour
Absentees: 7,13,18,30,40,53,57,59,64,66

Introduction to Mechatronics

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