Design of mechatronics systems
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This document provides an overview of key concepts in mechatronics engineering. It defines mechatronic systems as integrated electronic-mechanical systems combining sensors, actuators and digital electronics. Important life cycle factors for mechatronic systems include delivery, reliability, maintainability, serviceability, upgradeability and disposability. Modeling represents real systems using mathematical equations and logic. Key properties for the design process are strength, reliability, maintainability and manufacturability. Applications of mechatronic systems include fuzzy-based washing machines, auto-focus cameras, engine management systems and autonomous robots. Main operator risks are trapping, entanglement, impact and ejection.
![7. Write the materials that used in MEMS.
Many Microsystems uses microelectronic materials such as silicon, and gallium
arsenide [GaAs] for the sensing or actuating elements. Other elements such as quartz,
Pyrex, polymers, plastics and ceramics are commonly used in microelectronics.
8. Write the different types of micro sensors.
i) Acoustic wave sensors.
ii) Biomedical Sensors.
iii) Bio-Sensors.
iv) Chemical Sensors and
v) Optical Sensors.
vi)
9. Write the different types of actuation motions in micro devices.
i) Actuation using thermal forces.
ii) Actuation using shape-memory alloys.
iii) Actuation using piezoelectric crystals and
iv) Actuation using electrostatic forces.
v)
10. Define systemdesign.
It involves following steps:
i) Design considerations
ii) Selection of manufacturing processes
iii) Selection of materials and
iv) Selection of signal transduction.
PART B
11 a) Describe the design construction and working of micro motors with an application.
(Keywords: Diagram, Electrostatic Micromotor, Micromachines, Electrostatic forces,
and Rotary Motors.)
b) Discuss the design and working of micro robot.
(Keywords: Diagrams, Gripping, Parallel Plates, Drive Arm and Microgripper.)
12 a) With suitable example, discuss the working of a micro actuator.
(Keywords: Controlling, Actuating, Thermal forces, Memory alloys, Crystals and
Electrostatic force.)
b) Describe the construction and working of micro pump with its applications.
(Keywords: Diagram, Electrostatic Actuation, Silicon diaphragm, Upward motion,
And Piezopump.)](https://image.slidesharecdn.com/designofmechatronicssystems-191005085453/85/Design-of-mechatronics-systems-10-320.jpg)
Design of mechatronics systems
- 1. DEPARTMENT OF MECHATRONICS ENGINEERING MT6603 DESIGN OF MECHATRONICS SYSTEMS PREPARED BY, ARAVINDKUMAR B UNIT 1 FUNDAMENTALS PART A 1. Define Mechatronic Systems. The system changed from electro – mechanical systems with discrete electrical and mechanical parts to integrated electronic – mechanical systems with sensors, actuators and digital microelectronics. These integrated systems are called mechatronic systems. 2. Write the important life cycle factors in mechatronic systems. i) Delivery, ii) Reliability, iii) Maintainability, iv) Serviceability, v) Upgradeability and vi) Disposability. 3. Define Modeling. Modeling is the process of representing the behavior of a real system by a collection of mathematical equations and logic. 4. What are the properties should be considered for the design process? i) Design for strength or stiffness, ii) Design for reliability, iii) Design for maintainability and iv) Design for manufacture. v) 5. Write its applications of Mechatronics Systems. i) Fuzzy based washingmachine, ii) Autofocus Camera, iii) Engine management system and iv) Autonomous Robots. v) 6. Write the main area of operator risks. i) Trapping, ii) Entanglement, iii) Impact and iv) Ejection. 7. Define the term ergonomics. Ergonomics or human factors engineering is concerned with the application of the knowledge about the physical skills and limitations of a human being to provide a safe and effective working environment. 8. Define Simulation.
- 2. Simulation is the process of solving the model and is performed on a computer. Although simulations can be performed on analog computers, it is far more common to perform them on digital computers. The process of simulation can be divided into three sections: initialization, iteration and termination. 9. What are the key elements of a Mechatronics system? i) Physical System Modeling ii) Sensors and Actuators iii) Signals and Systems iv) Computers and Logic Systems and v) Software and Data Acquisition 10. Write any two differences between Tradition versus Mechatronics. Tradition: i) Bulky Systems, and ii) Complex Mechanisms Mechatronics: i) Compact Systems, and ii) Simplified Mechanisms. PART B 11 a). Compare hardware in loop simulation and control prototyping processes in the design of Mechatronics system. (Keywords: Block Diagram, Flow Chart, Programming, Intelligence Manufacturing, Feedback Process and Analyzed.) b). Discuss with flow diagram the stages of Mechatronics design process. (Keywords: Flow Diagram, Modeling, Simulation, Project Management, Design, Analysis, Real-Time Interface, Code generator and Embedded Processor Interface.) 12 a).What are the steps involved in the design of Mechatronics system? Explain. (Keywords: Modeling, Simulation, Prototyping and Development.) b). Why a system should be designed ergonomically? Explain with an example. (Keywords: Human Factors, Applications, Physical Skills, Limitations, Safe and Effective Working.) 13 a). Discuss in detail the advanced approaches in Mechatronics such as intelligent supervisory control structure and model based monitoring system. (Keywords: High Quality, Life Cycle, Plant Management, Intervention, Inspection system, Servo Control and Monitoring.) b). With the help of a block diagram, explain the key elements of a Mechatronics system. (Keywords: Block Diagram, Mechatronics, Simulation and Modeling, Automatic Control, Optimization, Mechanical Systems, Electrical Systems, Real time Interfacing and Computer systems.) 14 a). What are the applications of a Mechatronics system? What are its merits and demerits?
- 3. (Keywords: Washing Machine, pH Control system, Auto Focus Camera, Motor control, Engine Control, Tracking System and Surface Measurement.) b). Explain the role of modeling and simulation in the analysis of Mechatronics systems. (Keywords: Mathematical Equations, Real Systems, Physical Systems, Matter And Energy, Static and Dynamic, Heat transfer, Signals, Programming and Analog Computers.) UNIT 2 SYSTEM MODELLING PART A 1. What are various risks involved in designing safety Mechatronics systems? Operator safety and Machine safety are the two safety systems involved in Mechatronics system. 2. Mention the fields of application of two model categories. Bottom up design, Top-down design, Relationship of design strategies to modeling, Modeling for the specification, Modeling for the design are the fields of application. 3. What is transfer function? It is defined as the relationship between the input parameter and output parameter. 4. Define mathematical model. Model is defined as the group of objects that represent the entire system. It is a prototype that represents collection of entities like mathematical expressions such as state graphs, multi body diagrams. 5. What is modified analog approach? Analog approach includes the state graphs, multi body diagrams, circuit diagrams to represent a model. The implementation of the digital control systems replaces the electric circuits and prototype for the mechanics system. This technique is called modified analog approach. 6. Define viscous friction. Viscous friction is a measure of the resistance of the fluid which is being deformed by either shear stress or tensile stress. 7. State Faraday’s law. The induced electromotive force in any closed circuit is equal to the negative of the time rate of change of the magnetic flux through the circuit. 8. What is simulation? Simulation is the imitation of the real world process. It is the creation of the model using the mathematical calculations by software. Ex: ARENA.
- 4. 9. How over framing problem can be solved in a real time data acquisition and control system? It refers to the process of collecting the input data in digital form as rapidly accurately completely and economically. The basic instrumentation used may be a digital panel meter. 10. List the components required for real time interfacing. It is the process of interfacing the completed model with software equipment to view the internal operation of the model. The operation of the mechanical and electrical system is viewed. PART B 11 a) Explain with block diagram the principle of simulator plane used to couple simulators. (Keywords: Commercial Simulators, Simulator Backplane, Partitioning, Synchronization, Exchange of Data, Coupling and Lockstep algorithm.) b) Discuss methods adopted to carry out the following process. i) Model validation. (Keywords: Introduction, Empirical validity, Theoretical validity, Pragmatic validity, Heuristic validity, measured data and System identification.) ii) Model verification. (Keywords: Envisaged task, Applications, Errors, Boundary conditions, Chief Modeller, Plausibility tests, Causality, Balance principles, Value Range and Consistency of units.) 12 a) Explain the process of building up of models for the following system with an example. i) Mechanical system. ii) Pneumatic system. iii) Hydraulic system. (Keywords: Structural Modeling, Circuit Diagrams, State Graphs, Physical Modeling, Perspective of Modeling, Resulting equations and Experimental Modeling.) b) Explain a sequential control system with an example. (Keywords: Circuit Diagrams, State Graphs, Multi body diagrams, Finite elements and Dimensions.) 13 a) Discuss in detail the major components of a data acquisition and control system and their interconnections for a system with four sensors and two actuators. (Keywords: Sensors, Signal Conditioning, Multiplexing, Data Conversion, Data Processing, Data Handling and Transmission.) b) Elaborate on the necessary ingredients for the general I/O process required as part of a Mechatronics system. (Keywords: Communicates, Sensors, Actuators, Hardware and Software, Applications, Software and Speed.)
- 5. 14 a) Explain the fields of applications in model development. (Keywords: Simulation, Bottom up design and Top down design.) b) Explain the various modeling techniques. (Keywords: Structural Modeling, Physical Modeling and Experimental Modeling.) UNIT 3 SYSTEM INTERFACING PART A 1. Define RS 485 communication standard. RS 485 is an Electronics Industry Association (EIA) standard for multipoint communications. It supports several types of connectors, including DB-9 and DB-37. It can support more nodes per time. 2. What are the features of GPIO card used for data acquisition and control? GPIB (General purpose interface bus)is a standard for instrumentation communication and control for instruments from manufacturers. It is designed to connect the programmable instruments to their computers. 3. What is the function of a peripheral interface adopter? It is a peripheral integrated circuit providing parallel I/O interfacing capability for microprocessor systems. Some of the PIAs are Motorola MC6820 and MC6821. It is a 40 pin package. 4. What is the use of GUI card? It is a type of user interface item that allows people to interact with programs in more ways than typing such as computers, hand held devices such as MP3 players household appliances. It offers graphical icons and visual indicators to text based interfaces, typed command labels to provide information to the user. 5. Define data acquisition. The data acquisition system refers to the process of collecting the input data in digital form as rapidly, accurately, completely and economically. It is based on the properties of analog data and on the processing to be carried out. 6. Write the significance of DAQ. i) Resolution and accuracy. ii) The number of channels to be monitored. iii) Sampling rate per channel. iv) Signal conditioning requirement of each channel. vi) Cost. 7. What are the major components present in DAQ system. i) Sensors, ii) Actuators,
- 6. iii) Screw terminal panel(s), iv) General – purpose input/output card and v) Application software. 8. List the electrical characteristics of RS 232 interface. The RS 232 specifies the signaling rate between the DTE and DCE and a digital signal is used on all interchange circuits. The RS 232 standard specifies that logic “1” is to be sent as a voltage range -15v to -5v and that logic “0” is to be sent as a voltage in the range +5v to +15v. 9. Write down the significance of IEEE 488 standard interface. i) Token passing: The controller addresses the next controller SRQ Service request when the controller assigns modes. ii) The IEEE488 is most commonly used for data acquisition of HP peripherals. Programmable interfaces and drivers exist and simplify the development of microprocessor interfaces. 10. What is meant by Ethernet switch? It is used to build network connection between the attached computers. Hub will send incoming data packets to all ports. It operates on the data link layer of the OSI model. PART B 11 a) What are the features of a data acquisition system? (Keywords: Control Systems, Aircraft Control, Turbovisory instrumentation, Wide Temperature, Digital Signals, Resolution and Accuracy.) b) Describe the procedure including both hardware and software adopted to interface computer to real world process using general purpose input output cards. (Keywords: Samples, Algorithm, Converters, Channels, GPIO card, Modeling, Real time and Application Program.) 12 a) Describe the functions that are required for an interface. (Keywords: Communication, Monitors, keyboards, Printers, disks, Real time interface, Sensors, Actuators, Computer, and Real world process.) b) Explain about system interfacing using RS 232 interface. (Keywords: Binary data, Signals, Hardwired, Asynchronous, Unique rates, Connector, Signal Levels, Communicates, Signal Ground, Transmitted data, Receive data, Data format.) 13 a) What are the primary differences between RS 232, RS 422 and RS 485 serial interfaces? Explain. (Keywords: Controllers, Address, Length, Bus Network, Modules, Shielding, Grounds, Communications, Converters, Multi-drop, Transmit data, Receive data.) b) Explain the various IEEE 488 standard interface. (Keywords: Standard, Address space, Data Format, Transfer type, Timing, Speed, References, Driver, Bus length, Error Handling, Arbitration.)
- 7. 14 a) Explain the modes of operation of GUI card. (Keywords: Interface, Interact, Computers, Hand held devices, Commands, Icons, Indicators, Manipulations, Display, Dimensional, Operates, machine tools.) b) Explain Ethernet switch in detail. (Keywords: Half Duplex, Full Duplex, Receives data, Monitoring, Topology.) UNIT 4 CASE STUDIES ON MECHATRONIC SYSTEM PART - A 1. List the sensors used in engine management system. i) Oxygen sensor ii) Mass air flow sensor iii) Temperature sensor iv) Pressure sensor and v) Speed sensor. 2. What are the steps followed to process image of a surface to find its quality? i) Image grabber ii) Calculation circuit for extraction of characteristics iii) 2 D image memory for maximum brightness and iv) 3 D shape of the object. v) 3. Define embedded system. An embedded system is a computer system with a larger mechanical system or electrical system, often with real time computing constraints. Modern embedded systems are based on the microcontrollers (i.e CPUs with integrated memory). 4. What is PID? A proportional integral derivative is a generic control loop feedback mechanism widely used in industrial control systems. A PID controller calculates an “error” value as the difference between a measured process variable and desired set point. 5. What is the function of oxygen sensorin engine management system? An oxygen sensor is an electronic device that measures the proportion of oxygen in the gas or liquid being analyzed. It is frequently used to measure exhaust gas concentration of oxygen in internal combustion engines. 6. List out the hardware components required for the pick and place robot. i) Base ii) Arm iii) Shoulder iv) Elbow v) Pitch vi) Roll and vii) Wrist.
- 8. 7. What is fuzzy logic system and write its components? Fuzzy logic is a form of many valued logic; it deals with reasoning that is approximate rather than fixed and exact. It may have the truth value ranges between 0 and 1. 8. List out the parts used in pH control system. The pH control system requires one sensor for measuring pH and one actuator to control a metering device that adds a neutralizing agent to the solution. 9. Mention the uses of RFID. It is Radio Frequency Identification is wireless non contact use of radio frequency electromagnetic fields to transfer data for the purpose of automatically stored information. 10. Give two applications of fuzzy logic in Mechatronics. i) Washing machine ii) Micro electro mechanical system. PART B 11 a) Discuss in detail the data acquisition application of controlling the temperature of a hot/cold reservoir system. (Keywords: Water, Temperature, Mixing value, Reservoirs, output temperature, Thermistor, Analog input, Data acquisition cards, Position.) b) Explain the design of fuzzy based Washing machine system with suitable diagram. (Keywords: Process, Sensor System, Fuzzy Logic, Input, Output variables, Degree of dirt, Types, Information, Transparency, Cloths, Analyzed.) 12 a) Discuss the working of Autofocus camera with exposure control. (Keywords: Stress shielding, Implant, Micro Motion, Optical encoder, Micro Rotation, Simplicity, Accuracy, Reliability, Degrees, Directions.) b) In a conveyor system a robot is used to pick the object and place it on a drilling machine, With a block diagram explain the working of robot. (Keywords: Conveyor System, Robot, Arm, Manipulator, Data acquisition, Computer, Drill bit, Camera, Placing, Timing.) 13 a) Explain the Mechatronics system for Engine management system. (Keywords: Engine, System, Oxygen, Environment, Safety, Fuel, Consumption, Control.) b) What is image processing? How will you measure the surface using image processing? (Keywords: Material, Strength, Bridge, Blacktop, Testing, Strain gauges, Bolting, Amplification, Scaling factor.)
- 9. 14 a) How will you control the motion of DC motor and solenoids? (Keywords: Motor, Solenoids, Diagram, Control, Motion, Speed, Contact, Switch, Relay.) b) What is RFID? Explain the part identification and tracking technique using RFID. (Keywords: Radio, Frequency, Identification, Device, Signal, Transmits, Receives, Tracking.) UNIT 5 MICRO MECHATRONIC SYSTEM PART A 1. Define the principle of micro Mechatronics system. Micro systems technology enables the realization of very small systems by the use of technologies originally developed for the manufacturing of ICs. This technology push matches very well the continuous demand to further miniature a broad category of system. 2. What are the scaling laws used in Mechatronics systemdesign. i) Scaling in rigid body dynamics ii) Scaling in electrostatic forces iii) Scaling in electricity iv) Scaling in fluid mechanics and v) Scaling in heat transfer. 3. Write any two differences between Microsystems and microelectronics. Microelectronics: Stationary structures and Primarily 2-D structures. Microsystems: May involve moving components and Complex 3-D structures. 4. Define the term MEMS. MEMS stand for Micro Electro Mechanical systems. It is separate and distinct from the hypothetical vision of molecular electronics. It is made of components of 1 to 100 micrometers. 5. List out the applications of MEMS. i) Health care industry ii) Consumer products iii) Aerospace industry and iv) Telecommunication v) 6. What is LIGA and SLIGA process? It requires a special synchrotron radiation facility for deep X- ray lithography. This is not readily accessibility to most of the MEMS industry. These processes also require development of microinjection molding technology and facilities.
- 10. 7. Write the materials that used in MEMS. Many Microsystems uses microelectronic materials such as silicon, and gallium arsenide [GaAs] for the sensing or actuating elements. Other elements such as quartz, Pyrex, polymers, plastics and ceramics are commonly used in microelectronics. 8. Write the different types of micro sensors. i) Acoustic wave sensors. ii) Biomedical Sensors. iii) Bio-Sensors. iv) Chemical Sensors and v) Optical Sensors. vi) 9. Write the different types of actuation motions in micro devices. i) Actuation using thermal forces. ii) Actuation using shape-memory alloys. iii) Actuation using piezoelectric crystals and iv) Actuation using electrostatic forces. v) 10. Define systemdesign. It involves following steps: i) Design considerations ii) Selection of manufacturing processes iii) Selection of materials and iv) Selection of signal transduction. PART B 11 a) Describe the design construction and working of micro motors with an application. (Keywords: Diagram, Electrostatic Micromotor, Micromachines, Electrostatic forces, and Rotary Motors.) b) Discuss the design and working of micro robot. (Keywords: Diagrams, Gripping, Parallel Plates, Drive Arm and Microgripper.) 12 a) With suitable example, discuss the working of a micro actuator. (Keywords: Controlling, Actuating, Thermal forces, Memory alloys, Crystals and Electrostatic force.) b) Describe the construction and working of micro pump with its applications. (Keywords: Diagram, Electrostatic Actuation, Silicon diaphragm, Upward motion, And Piezopump.)
- 11. 13 a) Explain surface micro machining in detail. (Keywords: Building of Layers, Complex Masking, Sacrificial Layer, More Expensive, Thickness, Thin Film Materials, Complex Geometry, Adhesion, Interfacial Stress and Stiction.) b) Explain the scaling laws used for micro elements. (Keywords: Geometry, Rigid Body, Electrostatic, Electromagnetic, Fluid Mechanics And Heat Transfer.) 14 a) Explain the bulk micro-manufacturing in detail. (Keywords: Microsensors, Bulk Substrates, Sculptors, Shaping, Etching, Isotropic and Anisotropic, Orientation, Etch stop, Dopant controlled, Electrochemical Etch stop, Dry Etching, Plasma Etching, and Deep Reactive Ion Etching.) b) Explain the principle science and engineering disciplines involved in Microsystem design and manufacture with the neat diagram. (Keywords: Block Diagram, Electrochemistry, Electrohydrodynamics, Molecular Biology, Plasma Physics, Scaling Laws, Quantum Physics, Molecular Physics, and Engineering Disciplines.)