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Mechatronics

What is The History of Mechatronics?

It's always exciting when a new field emerges that offers opportunities to integrate various disciplines in a fresh
way. Mechatronics is such a field, and as it evolves, it's revolutionizing the way products are designed, from car rear-view
mirrors to automated door opening systems to robotics.

The obvious appeal of these new systems and devices to the business world and the public at large means we may never again
think of mechanical, electronic, and computer engineering as distinctly separate disciplines. Rather, as mechatronics continues to
synthesize these disciplines in the creation of exciting new technology and products, the divisions between these fields are
becoming less distinct.

What is Mechatronics?
Chances are, you may not have heard of the catch-all term "mechatronics," so in a nutshell, here's what it means: mechatronics
integrates various engineering disciplines in the design, development, and application of new smart devices. Students of
mechatronics learn how to create, fabricate, and test these new systems that we're all coming to rely on -- as well as products that
haven't yet been envisioned.

Take robotics, one of the main fields where the synthesis of mechanical, electronic, and computer engineering has had a profound
impact. Mechanical systems control gears and wheels, actuators and arms, while electronic systems control movement and
 produce power. Over the last couple of decades, the addition of computer-aided design software has revolutionized control
systems so that robotics operate in a more fluid manner, thus allowing ever more sophisticated uses and adaptations.

Another example is in the design of car rear-view mirrors. A few years ago a car mirror was just that. Now they have cameras,
and register temperature and compass direction by means of sensors. You can thank mechatronics for these improvements, which
have resulted in a more integrated approach to design.

Additional examples of mechatronics applications are:

 Anti-lock brakes
 Photocopiers
 Humidity-sensitive windshield wipers and clothes dryers
 Computer disk drives
You will also find mechatronic devices in agriculture, medicine, homes, commercial buildings, toys, and in aids for the disabled
and elderly.

Where Did Mechatronics Come From?

The word mechatronics was first used in Japan in the 1960s, and the field has indeed said to have grown out of robotics. Early on,
robot arms were uncoordinated and had no sensory feedback, but as advances were made in programming, sensor technology,
and controls, the robotic movements became more coordinated. Along the way, advances in mechatronics began to be used in
vending machines, auto-focus cameras, and door openers. With the advent of information technology in the 1980s,
microprocessors were introduced into mechanical systems, improving performance significantly. By the 1990s, advances in
computational intelligence were applied to mechatronics in ways that revolutionized the field.

The concept of applying the mechatronics approach to design, development, and fabrication has been popular for several decades
in Japan and Europe, but is only slowly gaining ground in the United States. Machines were traditionally designed by mechanical
engineers, and only afterward were control and programming solutions provided by computer and software engineers. As
familiarity with mechatronics has grown in this country, designers have come to see this more sequential approach as inefficient,
and are adopting more integrated design methods.

An Emerging Field for Students

Mechatronics has great appeal for those interested in how things are made and how they work. Students in a typical program
learn to design, develop, and troubleshoot programmable controllers, robotics, and integrated systems. The skills picked up in a
course of study can be used in the fields of maintenance and repair, quality assurance, research and development, and installation.

It's not news that many manufacturing jobs have disappeared in this country over the last 40 years. However, there are signs that
some manufacturing jobs are returning, but employers increasingly are demanding skilled workers to fill them. In fact, many
manufacturers offering these new jobs say they cannot fill jobs because of a lack of skilled workers.

Mechatronics is a promising field for people with skills in electronics, computers, automated machinery, and manufacturing.
Students with combined skills in mechanical, electrical and software engineering could have an advantage in getting hired. A
program that combines book theory and hands-on experience in robotics as well as these technologies will offer a student who
successfully completes the course work a good basis for possible advancement in the field.
Evolution of Mechatronics as a Contemporary Design Paradigm

The industrial, semiconductor, and information revolutions have led to major technological
advancements in the design and operation of engineering products.
 

Industrial Revolution
 
The industrial revolution enabled design of products and processes to convert and transmit ever-
increasing amounts of energy for industrial activities. Engineering designs of this era performed
operations of motion transmission, sensing, actuation, and computation using mechanical
components e.g., cams, gears, levers, linkages, etc. Watt's flyball governor typifies the
engineering designs of this era. Unfortunately, purely mechanical systems suffer from power
amplification inability and energy losses due to tolerances, inertia, and friction (Tse and Morse,
1989).
 
Semiconductor Revolution
 
The semiconductor revolution leading to the development of integrated circuit (IC) technology
created the next key impact on the design of engineering products. On the actuation side,
through cost effective, miniaturized, power electronics for efficient power amplification,
semiconductor technology provided a practical means of delivering required levels of power to
mechanical devices via electrical means. Similarly, on the sensing side, semiconductor
technology afforded an ability to condition and encode physical measurements as analog/digital
signals. Furthermore, hardwired, onboard, analog/digital electronics provided rudimentary
computational abilities to mechanical devices. Rapid developments in electro-mechanical sensing
and actuation hardware, which had begun in an earlier era, further fueled the adoption of
semiconductor technology in the design and operation of mechanical devices.

 
 
An Integrated Circuit Chip
 
 
 
 
Analog to Digital Converter
 

 
 
 
 
Operational Amplifier
 
 
 
Information Revolution
 
In the closing decades of 20th century, as the semiconductor and information technology
industries experienced explosive growths, the computing hardware became ubiquitous and
cheap. A momentous transformation in the design and operation of mechanical devices and
systems began to unfold, with information technology emerging as a technology enabler
imparting intelligence to numerous products, processes, and machines. Microprocessors began
replacing precision mechanical components, e.g., precision-machined camshaft, which in many
applications functions as a timing device. In addition, programmability of microprocessors
provided a versatile and flexible alternative to the hardwired analog/digital computational
hardware. Integrated computer-electrical-mechanical devices now became capable of converting,
transmitting, and processing both the physical energy and the virtual energy (information). Thus,
in recent years, engineers began developing highly efficient products and processes by judicious
selection and integration of sensors, actuators, signal conditioning, power electronics, decision
and control algorithms, and computer hardware and software.
 

 
 
 
 
 
Data Acquisition Board
 

 
 
Stamp microcontroller
 
 

The History of Mechatronics

The history of mechatronics is not lengthy.

 The name “mechatronics” was originated in 1969 by senior

engineer Tetsura Mori.
 He was working for a Japanese company called Yaskawa Electric
Corporation that was famous for building mechanical factory
equipment.
 At that time, Yaskawa Electric Corporation was using some
electronic features for manufacturing mechanical equipment. Mori
wanted to introduce a technical term for that new technology, so he
combined the two technical words ‘mechanical’ and ‘electronics’ and
created the new word “Mechatronics.”
 In 1970, Yaskawa applied to make this word a registered brand
and got the rights in 1973. But, at that time this term didn’t gain
much popularity. After the 1980s, the term started gaining popularity
because of its useful features.
 Earlier, this term was based on only some electrical and electronic
computers, but after the 1980s, the use of computer technology was
integrated. The controlling and functioning of machines became
much easier by use computer hardware and software. This allowed
the start of manufacturing of a variety of products of any size with
very high accuracy and comparatively low cost.
 Mechatronics, although still a new term as compared to other well
established branches of engineering, now seems to be firmly
established. Now, individuals and industries around the world use
the term freely.
 At the research and development level, mechatronics is classified
into ten technical areas: Motion Control, Robotics, Automotive
Systems, Intelligent Control, Actuators and Sensors, Modeling and
 Design, System Integration, Manufacturing, Micro Devices and
Optoelectronics, and Vibration and Noise control.

Now the application area of mechatronics is extremely broad. This

technology is firmly used in the automation of machines, servo-
mechanics, industrial goods, biomedical systems, energy and power
systems, vehicular systems, data communication systems, computer
aided design, CNC and DNC systems, etc. Robotics is directly
dependent upon this technique. There are uncountable examples where
this technology is used. But proper application, utilization, and
maintenance of these high technology products and systems are also
some important characteristics because these factors are responsible for
the enhancement of productivity and the quality of the product and
system.

1. Relation of Automation in Mechanical Engineering

Automation
Automation is the technology by which a process or procedure is performed with minimal human
assistance.[1] Automation[2] or automatic control is the use of various control systems for operating
equipment such as machinery, processes in factories, boilers and heat treating ovens, switching on
telephone networks, steering and stabilization of ships, aircraft and other applications and vehicles
with minimal or reduced human intervention.
Automation covers applications ranging from a household thermostat controlling a boiler, to a large
industrial control system with tens of thousands of input measurements and output control signals. In
control complexity, it can range from simple on-off control to multi-variable high-level algorithms.

Mechanical and automation engineers are mainly focus on designing and manufacturing of
machines. Engineers design and assemble engines and power plants, structures and vehicles
of all sizes and deals with use of machines, control systems and information
technologies. The future of mechanical and automation engineering certainly offers a variety
of opportunities for professionals entering the field. Students studies the principles of
mechanics, materials and energy to design as well as manufacture machines and devices of
all kinds. 
 
Career Prospects
 
Mechanical engineering is one of the top most career choices made by students in India.
There are a lots of career opportunities in this field for young aspirants. Graduates from this
field are mainly employed in manufacturing firms. Mechanical engineers can seek
employment in private or public sector industries of various types. They can also find job in
government departments such as CPWD, defense, PWD, posts and telegraphs. Other sectors
such as electronics, chemical, power plants, steel plants, agricultural, space research
institutes, automobile and aeronautical as well as the railways, need mechanical engineers to
design and maintain their machinery.

Candidates with postgraduate degree or with additional management degree can find work in
executive and managerial positions. In agricultural division, mechanical engineers play a
 major role by establishing service centers for maintenance of pump sets, tractors, electric
motors, oil engines and other agricultural equipments. Candidates who are interested in
research activities can work with many public/private sectors research organizations.
Professionals in this career can also opt for teaching jobs in universities and colleges.
Postgraduate students with experience can also seek employment in abroad countries.

Automation generally means introducing computerized controllers into the existing

Mechanical systems. The computerization helps in restructuring the methods, eradicating
errors, growing productivity, and increasing the overall functional efficacy. In today's world
With the advancement of Technology, high-speed computers and sensors have become
very cheap. This has resulted in the growth of a new interdisciplinary branch involving
computer science, electrical and mechanical engineering called robotics, Mechatronics, and
automation. I strongly feel that robotics and automation should be advanced to assist
humans in doing tasks which are considered to be difficult or dangerous to do
manually; not to replace humans.

Nowadays, many types of research are going on for automating the Mechanical process like
welding, drilling, milling, lathe, grinding etc which might have huge errors and might be a
time-consuming process when done manually. With the use of automated machines in the
manufacturing sector, more complex and sophisticated products can be manufactured
with high quality and precision. And yes, all of these systems do require human
intervention for giving necessary instructions or to change the course of a specific process.

For example, I am working on developing a system for automating the welding process by

sensing the geometry of any irregular cracks on the metal surface by taking necessary
inputs from the user. Traditionally these kinds of irregular cracks are welded by highly
skilled human welders. Since welding process produces bright sparks and harmful gases, the
welders have to work in the perilous state. The welding environment is highly harmful to
welder’s health, especially eyes. So, it's very important to automate these kinds of hazardous
processes.

Similarly, in the Advanced manufacturing laboratory of Northwestern University, a research

is going on to automate the forming process using robots. A tri-pyramid robot has been
developed for doing the double-sided incremental forming process. Using this robot
forming can be done with precision up to few micrometres.

Most of the latest commercial vehicles are built width active mass suspension
system which senses the displacement between tire and chassis and the controllers act
accordingly for effectively damping the disturbance created by the unevenness in the road.
It gives a highly comfortable ride for the passengers. This is also a kind of mechanical
automation.

Complete automation involves giving machines the ability to think and act like humans. For
doing so it is necessary to use machine learning and artificial intelligence which is currently
very expensive and not that reliable. Automation has just added spice and broadened the
field of Mechanical engineering. In future, it is expected that these branches will get
advanced and smart self-regulating machines will completely replace humans. If it
happens, blue-colour jobs will be completely eradicated and replaced by perspicacious
machines. But do we really wish to live in such kind of world, is a matter of debate. Even if
the world's most intelligent robot cooks food, it can't get better than the food cooked
by our mother isn't so!!!!
 1.Types of Automated Manufacturing Sytems
and their examples
Manufacturing Applications Of Automation And
Robotics

One of the most important application areas for

automation technology is manufacturing. To many people, automation
means manufacturing automation. In this section, the types of
automation are defined, and examples of automated systems used in
manufacturing are described.
Three types of automation in production can be distinguished:
(1) fixed automation, (2) programmable automation, and (3) flexible
automation.

Fixed automation, also known as “hard automation,” refers to an

automated production facility in which the sequence of processing
operations is fixed by the equipment configuration. In effect, the
programmed commands are contained in the machines in the form of
cams, gears, wiring, and other hardware that is not easily changed
over from one product style to another. This form of automation is
characterized by high initial investment and high production rates. It
is therefore suitable for products that are made in large volumes.
Examples of fixed automation include machining transfer lines found
in the automotive industry, automatic assembly machines, and certain
chemical processes.

Programmable automation is a form of automation for producing

products in batches. The products are made in batch quantities
ranging from several dozen to several thousand units at a time. For
each new batch, the production equipment must be reprogrammed
and changed over to accommodate the new product style. This
reprogramming and changeover take time to accomplish, and there is
a period of nonproductive time followed by a production run for each
new batch. Production rates in programmable automation are
generally lower than in fixed automation, because the equipment is
designed to facilitate product changeover rather than for product
specialization. A numerical-control machine tool is a good example of
programmable automation. The program is coded in computer
memory for each different product style, and the machine tool is
controlled by the computer program. Industrial robots are another
example.

Flexible automation is an extension of programmable automation. The

disadvantage with programmable automation is the time required to
reprogram and change over the production equipment for each batch
of new product. This is lost production time, which is expensive. In
flexible automation, the variety of products is sufficiently limited so
that the changeover of the equipment can be done very quickly and
automatically. The reprogramming of the equipment in flexible
automation is done off-line; that is, the programming is accomplished
at a computer terminal without using the production equipment itself.
Accordingly, there is no need to group identical products into batches;
instead, a mixture of different products can be produced one right
after another.

1.Social and Safety issues in Automation