Mechatronics Systems Design MPE 301

Mechatronics Systems Design

MEC 301

Grading system
Final Exam 50
Midterms 25
Sheets 15
Oral + attendance + Project 15

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Mechatronics Systems Design MPE 301

Time table

Google classroom codes

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Mechatronics Systems Design MPE 301

What mechatronics systems design from you

viewing point?

Table of Contents :
Chapter 1: MECHATRONICS SYSTEM DESIGN
Chapter 2: MODELING AND SIMULATION OF SYSTEMS
Chapter 3: SENSORS AND TRANSDUCERS
Chapter 4: ACTUATING DEVICES
Chapter 5: ELEMENTS OF INFORMATICS
Chapter 6: SYNTHESIS OF MECHATRONICS SYSTEMS

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Mechatronics Systems Design MPE 301

Ref. Materials
1. Mechatronics System Design, 2nd ed, Devdas Shetty and
Richard A. Kolk, Cengage Learning, 2011.
2. Mechatronic Systems Design Methods, Models, Concepts,
Kristof Richmond, Springer-Verlag Berlin Heidelberg, 2012.

Dr. Mahmoud Mohamed Atta

Email; [email protected]
Office: Mechanical Engineering building, 5th floor.

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Mechatronics Systems Design MPE 301

CHPTER 1
Mechatronics System Design
Mechatronics is a methodology used for the optimal design of electromechani-
cal products.
Methodology is a group of procedures, and
rules with experience used in a specific field.

Mechatronics integrates four fundamental

fields: electrical, mechanical, computer
science, and information technology into one.

A common task in electromechanical system is

the use of computer algorithm to modify the
behaviour of a mechanical system.
Electronics are used to transduce information between the computer science
and mechanical elements.

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Mechatronics Systems Design MPE 301

The most wisely used design procedures of an electromechanical design

system is performed in three steps;
1. Complete mechanical system design.
2. Complete power and microelectronics design.
3. Control algorithm design and implementation.

The major drawback of this approach is the creation of new constraints on the
latest task by fixed the earliest one. So, control designs often are not efficient
because of these additional constraints.

Mechatronics related fields

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For improving the results of mechatronics system design, an integration

between mechanical, electrical, and computer systems with information
systems for the design and manufacture of products and processes, at all
stages of design.

Mechatronics key elements

Its basic idea is to apply new controls to achieve higher level of performance
from a mechanical device.

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Mechatronics Systems Design MPE 301

1. Integrated Design in Mechatronics

The parallel engineering of the mechatronics approach depends heavily on the
use of system modelling and simulation throughout the design and prototyping
stages.

It is important to program the model in a form that can be used and modified
by engineers from different fields. Such forms include block diagrams, flow
charts, state transition diagrams, and bond graphs.

The most widely used form is the block diagram, which is extremely flexible,
low in cost, and can be coded (translates the block diagram) into a high-level
language (C or similar language) suitable for system implementation.
(Simulink TM software)

Compared with basic design and progressing through the manufacturing

phase, mechatronic design optimizes the parameters at each phase to
produce a quality product in a short-cycle time.

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Mechatronics Systems Design MPE 301

The integration within a mechatronic system is performed through the

combination of hardware (components) and software (information processing).

Mechatronic design supports the concepts of concurrent engineering, which its

advantages are;

• Better definition of the product without late changes.

• Manufacturing and assembly design accepted in the early stage.
• Process on how the product development is well defined.
• Better cost estimates.
• Decrease fences between design and manufacturing.

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Mechatronics Systems Design MPE 301

With concurrent engineering the designed product likely have;

• High quality • Robustness
• Low cost • Time to market
• Customer satisfaction

2. The Mechatronics Design Process

Mechatronics reduce time and cost of present design processes with; at the same time
1. Engineers of various fields work simultaneously, as one team, which
eliminates design incompatibilities and reduces design time (fewer returns).
2. Extensive use of powerful simulations models and reducing needs for
prototypes reduced Design time.
This over come traditional design problems; engineers work separately, limit
ability to adapt for mid-design changes, and dependent upon multiple
prototypes.

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Mechatronics Systems Design MPE 301

Mechatronics Design cycle

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Hardware-in-the-Loop Simulation
In the prototype step, many of the non-computer subsystems of the model
(sensors, actuators and process elements) are replaced with actual hardware.
This provides the interface signals necessary to connect the hardware
subsystems back to the model.

HARDWARE-IN-THE-LOOP MODEL

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3. Mechatronics Key Elements

1. Information Systems
Information systems include all forms of information transmission; signal
processing, control systems and analysis techniques.

An information system is a combination of; communication systems, signal

processing, control systems, and numerical methods.

Mechatronics applications are concerned with modelling, simulation, automatic

control, and numerical methods for optimization.

• Modelling and Simulation

Modelling is the representing of the behaviour for a real system by a
collection of mathematical equations and logic (static or dynamic).

External fixed-value is called a parameter, while an external chang is called an

input signal and all model output information is output signals.

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Mechatronics Systems Design MPE 301

Model can be expressed into; text-based programming languages (one must

be familiar with this language in order to understand the model) or block
diagram.

Basic blocks

Simulation is the process of solving the model and is performed on a

computer. This process can be divided into three sections: initialization,
iteration, and termination.

The iteration section solves any differential equations present in the model
using numerical integration and/or differentiation.

Most methods employed for the numerical solution of ordinary differential

equations are based on the use of approximating polynomials.

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Mechatronics Systems Design MPE 301

Optimization solves the problem of distributing limited resources throughout a

system. In mechatronics, optimization is primarily used to establish the optimal
system configuration.

Terminology Meaning
Design variables Resources
Objectives System behaviour
Constraints Governing relationships
2 Mechanical Systems
Mechanical systems are concerned with the behaviour of matter under the
action of forces. Such systems are classified as solid (rigid, deformable), or
fluid (compressible and incompressible).
Newtonian mechanics provides the basis for most mechanical systems,
consists of three independent and absolute concepts: space, time, and mass.
A fourth concept, force, is present but depends of the other three.

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Mechatronics Systems Design MPE 301

Most mechatronic applications involve rigid-body systems, which relies on six

fundamental laws;
F is the force acting on a body
1. First law of Newton :
F=0 the body is at rest and will remain
Or the body moves at straight line with constant speed.
2. Second Law of Newton;
F=ma m mass and a is the acceleration
3. Third Law of Newton; The contact force between 2 bodies at contact point
have the same magnitude, line of action, and opposite sense.
4. Newton’s Law of Gravitation:

M and m are 2 masses, r distance between them, and G = 6.674 30 x 10-11 m3

kg-1 s-2

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Mechatronics Systems Design MPE 301

4. Rules of resulting forces acting on a body.

5. Principle of Transmissibility;: The acting point of any external force on a
body may be transmitted anywhere along the force’s line of action without
affecting the resulting force acting on that body.
The system of units are;
System International (SI) system m-k-s
Gaussian system cm - g - s
British engineering system foot – pound - second

3 Electrical Systems
Electrical systems are concerned with three fundamental quantities: charge,
current (transmit energy between 2 points), and voltage (or potential).
Electrical systems has two categories: power and communication systems.
Communication systems used low-energy electrical signals between points
and is used for information storage, processing, and transmission.

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The following electrical components are frequently used;.

• Motors and generators • Sensors and actuators (transducers)
• Solid state devices including computers
• Circuits (signal conditioning and impedance matching, including amplifiers)
• Contact devices (relays, circuit breakers, switches, slip rings, mercury
contacts, and fuses)
Electrical applications in mechatronic systems require an understanding of DC
and AC circuit analysis, including impedance, power, and electromagnetic and
semiconductor devices (such as diodes and transistors).

Electric circuit, the closed path where current flow, consists of electrical
elements connected by wires. Wires are assumed to be ideal or perfect
conductors, which mean that; potential is the same within the circuit and no
charge will be stored through it.

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Mechatronics Systems Design MPE 301

Expression Meaning
Open circuit There are two points in the circuit are not connected
Short circuit No elements in the circuit except wire
Node Point at which two or more circuit elements are connected.
Branch path between two nodes
Circuit calculating voltages and currents in a circuit, given the circuit
analysis diagram and a description of each element.

Circuit analysis is the process of calculating all voltages and currents in a

circuit given the circuit diagram and a description of each element. Circuit
analysis is based on two Kirchhoff’s laws
Kirchhoff ’s current law: sum of all currents entering a node is zero.
Kirchhoff ’s voltage law: sum of all voltage drops around a closed loop is zero

Behaviour of an electrical system element can be described with its

impedance, impedance (Z), or V–I characteristic.

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Mechatronics Systems Design MPE 301

Circuit analysis techniques are depending on the Its

time (DC or AC). Element type impedanc
e
Resistance Z=R
R

Power is the rate of energy transfer (it units is watt

Capacitor
= j/s)
Inductor
When current flows through an electrical circuit, power is produced. But a part
of this power can be converted to other forms (heat). That is reduced the
efficiency of the circuits (example of diesel-electric locomotive)

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Mechatronics Systems Design MPE 301

4 Sensors and Actuators

Sensors are required to monitor machines’ or processes’ performance, and
can evaluate operations, machine health, inspect work in progress, and
identify part and tools.
Sensors are needed to provide real time information for controllers to identify
problems with machines and its environment, so it should be located as near
as possible to measured quantity (surface quality, temperature, vibrations, and
flow rate of cutting fluid).
Accuracy and repeatability are critical capabilities of the sensor to provide the
reliability. The desirable features for selecting measuring devices are;
High accuracy High precision
Wide operating range High speed of response

Ease of calibration Minimum drift

High reliability Low cost

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Mechatronics Systems Design MPE 301

When measuring different variables, several characteristics become important:

the dynamics of the sensor, stability, resolution, precision, robustness, size,
and signal processing.
Actuation involves a physical action on the process (ejection work piece from
a conveyor system).
Actuators are usually electrical, mechanical, fluid power or pneumatic based.
They transform input power into mechanical outputs such as force, angle, and
position.
Actuators can be classified into;
1. Electromagnetic actuators, (e.g., AC and DC electrical motors, stepper
motors, electromagnets)
2. Fluid power actuators, (e.g., hydraulics, pneumatics)
3. Unconventional actuators (e.g., piezoelectric, magnetostrictive, memory
metal).

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5 Real-Time Interfacing
Simulation of a mathematical model is unrelated to real time.
The process of simulation requires that all cause and effect equations in the
model be ordered with inputs on the left and outputs on the right prior to
simulation. The sorted equations are solved with several iterations (loop) to
reach the required solution.
In mechatronics, the main purpose of the real-time interface system is to
provide data acquisition and control functions for the computer.
The control function produces an analog approximation as a series of small
steps. Thus, for mechatronic applications, real-time interfacing includes analog
to digital (A/D) and digital to analog (D/A) conversion, analog signal
conditioning circuits, and sampling theory.

5 Applications in Mechatronics

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Arabic Republic of Egypt ‫جمهورية مصر العربية‬
Zagazig University ‫جامــــعة الزقازيق‬
Faculty of Engineering ‫كلية الهندســـــــة‬
Mechatronics Engineering Program ‫برنامج هندسة الميكاترونيات‬
Mechatronics System Design ‫تصميم منظومات الميكاترونيات‬

Sheet 1
Mechatronics System Design
1. Define Mechatronics.
2. What are the fundamental fields of Mechatronics?
3. Discuss the key elements of automatic concrete mixer, from your point of view.
4. Discuss the integrated design in Mechatronics and state its advantages.
5. “Mechatronics reduce time and cost of present design processes” discuss this
phrase.
6. What are the basic blocks in the block diagram and what their meaning?
7. What are the desirable features for selecting measuring devices?
8. What is the main purpose of the real-time interface system? And how the signals
and date transmitted between the different elements to computer and vice versa.