Introduction to Mechatronics

Delbante Alebachew
 INTRODUCTION

➢ “The word, mechatronics is composed of mecha from

mechanics and tronics from electronics.

➢ In other words, technologies and developed products will

be incorporating electronics more and more into
mechanisms, intimately and organically, and making it
impossible to tell where one ends and the other begins.”

T. Mori, “Mechatronics,” Yasakawa Internal Trademark Application

Memo,21.131.01, July 12, 1969
2
➢ “Integration of electronics, control engineering, and mechanical
engineering.”
W. Bolton, Mechatronics: Electronic Control Systems in Mechanical Engineering, Longman, 1995

➢ “Application of complex decision making to the operation of

physical systems.”
D. M. Auslander and C. J. Kempf, Mechatronics: Mechanical System Interfacing, Prentice-Hall, 1996

.
➢ “Synergistic integration of Mechanical Engineering with
Electronics and Intelligent Computer Control in the design and
manufacturing of industrial products and processes.”
F. Harshama, M. Tomizuka, and T. Fukuda, “Mechatronics-what is it, why, and how?-and editorial,”
IEEE/ASME Trans. on Mechatronics, 1(1), 1-4, 1996.

3
➢ “Synergistic use of precision engineering, control theory,
computer science, and sensor and actuator technology to
design improved products and processes.”
S. Ashley, “Getting a hold on mechatronics,” Mechanical Engineering, 119(5),
1997.
➢ “Methodology used for the optimal design of
electromechanical products.”
D. Shetty and R. A Kolk, Mechatronics System Design, PWS Pub. Co., 1997.

➢ “Field of study involving the analysis, design, synthesis,

and selection of systems that combine electronics and
mechanical components with modern controls and
microprocessors.”
D. G. Alciatore and M. B. Histand, Introduction to Mechatronics and
MeasurementSystems, McGraw Hill, 1998.
4
DISCIPLINARY FOUNDATIONS OF MECHATRONICS
➢ Combines Mechanical, Electrical, and Software engineering for the
purpose of designing smart machines that manage complexity,
uncertainty, and communication in engineering systems

5
MECHATRONICS SYSTEM

6
MECHATRONICS SYSTEM

7
ELEMENTS OF MECHATRONICS—MECHANICAL

➢ Mechanical elements refer to mechanical structure,

mechanism, thermo-fluid, and hydraulic aspects of a
mechatronics system.

➢ Mechanical elements may include static/dynamic

characteristics.

➢ A mechanical element interacts with its environment

purposefully.

➢ Mechanical elements require physical power to produce

motion, force, heat, etc.
8
ELEMENTS OF MECHATRONICS—MECHANICAL

9
ELEMENTS OF MECHATRONICS—ELECTROMECHANICAL

➢ Electromechanical elements refer to:

• Sensors: A variety of physical variables can be measured using
sensors, e.g., light using photo-resistor, level and displacement
using potentiometer, direction/tilt using magnetic sensor, sound
using microphone, stress and pressure using strain gauge, touch
using micro-switch, temperature using thermistor, and humidity
using conductivity sensor

• Actuators: DC servomotor, stepper motor, relay, solenoid, speaker,

light emitting diode (LED), shape memory alloy, electromagnet,
and pump apply commanded action on the physical process,
hydro/pneumatic cylinders

• IC-based sensors and actuators (digital-compass, -potentiometer,

10

etc.).
ELEMENTS OF MECHATRONICS—ELECTROMECHANICAL

11
ELEMENTS OF MECHATRONICS—ELECTRICAL/ELECTRONIC

Electrical elements refer to:

➢ Electrical components (e.g., Resistor (R), Capacitor (C), Inductor
(L), transformer, etc.), circuits, and Analog signal
Electronic elements refer to:
➢ Analog/digital electronics, transistors, thyristors, opto-isolators,
operational amplifiers, power electronics, and signal
conditioning
➢ The electrical/electronic elements are used to interface
electromechanical sensors and actuators to the control
interface/computing hardware elements

12
ELEMENTS OF MECHATRONICS—ELECTRICAL/ELECTRONIC

13
ELEMENTS OF MECHATRONICS—CONTROL
INTERFACE/COMPUTING HARDWARE
Control interface hardware allows analog/digital
interfacing
❖ Communication of sensor signal to the control computer and
❖ Communication of control signal from the control computer to
the actuator
Control interface/computing hardware elements refer to:
❖ Analog-to-Digital (A2D) converter,
❖ Digital-to-Analog (D2A) converter,
❖ Digital input/output (I/O),
❖ Counters, Timers,
❖ Microprocessor, Microcontroller,
❖ Data Acquisition and Control (DAC) board, and
14
❖ Digital signal processing (DSP) board
➢ Control computing hardware implements a control
algorithm, which uses sensor measurements, to compute
control actions to be applied by the actuator.

15
ELEMENTS OF MECHATRONICS—
COMPUTER/INFORMATION SYSTEM
Computer elements refer to Software utilized to perform:
 Computer-aided dynamic system analysis,
optimization, design, and simulation
 Rapid control prototyping
 Hardware-in-the-loop simulation
 PC-based data acquisition and control

ADMS
MATLAB
LabVIEW
. . . 16
 MECHATRONICS APPLICATIONS

 Smart consumer products: home security, camera,

microwave oven, toaster, dish washer, laundry washer-
dryer, climate control units, etc.
 Medical: implant-devices, assisted surgery, haptic, etc.

 Defense: unmanned air, ground and underwater vehicles,

smart munitions, jet engines, etc.
 Manufacturing: robotics, machines, processes, etc.

 Automotive: climate control, antilock brake, active

suspension, cruise control, air bags, engine management,
safety, etc.

17
Examples

18
 Mechatronics Systems
Computers

Cars
Tools

Consumer Stealth Bomber

Electronics

High Speed Trains

MEMS
Micro to Macro
Applications
 Mechatronics Systems
-Manufacturing Applications-
CNC Bending
•Fully automated bending: load
sheet metal and the finished bent
parts come out
•Can bend complex shapes
 Mechatronics Systems
-Manufacturing Applications-

CNC Machining

Advantages
•Deliver the highest accuracies
•Can create very complex shapes
 Mechatronics Systems
-Transportation Applications-
Automobiles
Typical Applications
•Brake-By-Wire system
•Steer-By-Wire
•Integrated vehicle dynamics
•Camless engines
•Integrated starter alternator

•Reliability
•Reduced weight
•Fuel economy
•Manufacturing flexibility
•Design freedom
•Advanced safety features
•Cost
 Mechatronics Systems
- Door System/Module-

“Smart” Mirror motor-

unit pin-header “Smart”
Doorlock
CAM Bus

“Smart” Window Lift-unit Switchboard with

CAN Bus Gateway
 Mechatronics Systems
-Transportation Applications-
High Speed Trains
•Train Position and Velocity
constantly monitored from
main command center.
•Error margin in scheduling no
more than 30 seconds
JR-Maglev
•Fastest trains use magnetic Top Speed: 574 km/h (357 mph)
levitation Country: Japan

Magnetic Levitation

Transrapid
Top Speed: 550 km/h (340 mph)
Country: German
 Mechatronics Systems
-Transportation Applications-

Systems Uses Segway

•Tilt and pressure sensors
•Microcontroller
•Motors
•Onboard power source

Advantages
•Simple and intuitive
personal
transportation device
 Mechatronics Systems
-Smart Robotics Application-
BigDog

System Can
•Carry 340 lb Advantages
•Run 4 mph •Robot with rough-terrain mobility that could
•Climb, run, and walk carry equipment to remote location.
•Move over rough terrain
 Mechatronics Systems
-Smart Robotics Aplications-

Vacuum Floors
•Robots can vacuum floors and
clean gutters so you don't have to.

Cleans Gutter
 Mechatronics Systems
-Space Exploration Application-
Phoenix Mars Lander's

System Can
•Collect specimens
•Has automated onboard
lab for testing specimens

Advantages
•Robot that can travel to other
planets and take measurements
automatically.
 Mechatronics Systems
-Medical Applications-

Prosthetics
•Arms, Legs, and other body parts
can be replaced with
electromechanical ones.
 Mechatronics Systems
-Medical Applications-
Pace Maker
•Used by patients with slow or
erratic heart rates. The pacemaker
will set a normal heart rate when it
sees an irregular heart rhythm.

Implantable Defibrillation
•Monitors the heart. If heart
fibrillates or stops completely it will
shock the heart at high voltage to
restore a normal heart rhythm.
 Mechatronics Systems
-Defense Applications-

•Advanced technology is making

our soldiers safer. Stealth Bomber
•Some planes can now be flown
remotely.

Unmanned Aerial Vehicle

 Mechatronics Systems
-Sanitation Applications-

System Uses
•Proximity sensors
•Control circuitry
•Electromechanical valves
•Independent power source

Advantages
•Reduces spread of germs by making
device hands free
•Reduces wasted water by automatically
turning off when not in use
 Mechatronics Systems
-Sanitation Applications-
Systems Uses
•Motion sensors Paper Towel Dispenser
•Control circuitry
•Electromechanical
actuators
•Independent power source

Soap Dispenser

Advantages
•Reduces spread of germs by making
device hands free
•Reduces wasted materials by
controlling how much is dispensed
 Mechatronics Systems
-Smart Home Applications-

Solution Power Supply

Washing Machine
Rectifiers/Regulator

Pressure Sensor
MPX5006/MPX2010
Mechatronics Systems
-Smart Home Applications-

Smoke Detector System

BENEFITS OF MECHATRONICS

 More features
 Higher precession
 User friendly
 More flexible
 Lower cost, Efficient
 Environment friendly
 Smaller geometry
 More reliable
 Safer

36
 1.2 SYSTEM

 System can be thought of as a box which has an input and an

output and where we are not concerned with what goes on inside
the box but only the relationship between the output and the
input.

37
 1.2.1 MEASUREMENT SYSTEM
 A black box used for making measurements.
 It has the input the quantity being measured and output the value
of the quantity.
 Example: temperature measurement system: a thermometer has
an input of temperature and an out put of a number on a scale.

Input Output
Sensor Signal
Display
Quantity conditioner Value of the
being
measured
quantity

38
Measurement System
 Sensor: responds to the quantity being measured by
giving as its output a signal which is related to the
quantity.
 Example: thermocouple- input: temperature
- output: an emf
 Signal conditioner: takes the signal from the sensor and
manipulates it into a condition which is suitable for
either display, or, in case of control system, for use to
exercise control.
 Example: Amplifier-input: output from thermocouple
-output: a bigger signal
 Display: system where the output from the signal
conditioner is displayed.
 Example: a pointer moving across a scale or a digital readout.
39
An Example of Measurement System

40
 1.2.2 CONTROL SYSTEM

 It can be thought as a black box which is used to control

its output to some particular value.
 Example: A domestic central heating control system
: Shaft speed control

Input Output
Central Heating
Required Temperature of
Control system
temperature the set value

41
 CONT…
There are two basic forms of control system, one being
called open loop and the other closed loop.

➢ Open loop systems have the advantage of being

relatively simple and consequently low cost with generally
good reliability. However ,they are often inaccurate since
there is no correction for error.

➢ Closed-loop systems have the advantage of being

relatively accurate in matching the actual to the required
values. They are, however , more complex and so more
costly with a greater chance of breakdown as a
42
consequence of the greater number of components.
 Example of Open Loop control System

Input Output
Switch Electric fire
Electric
Decision to Temperature
power
switch on or off change

 Heating a room: an open loop system-an eclectic fire with a

1kw and 2kw selection switches.
▪ 1kw -- if the room is not required to be at too high temperature.
▪ 2kw -- if the room is required to be at too high temperature.

 If there are changes in the conditions, perhaps someone

opening a window, there is no way the heat output is
adjusted to compensate. There is no information feedback to
the element to adjust it and maintain a constant 43
temperature.
 ELEMENTS OF A CLOSED LOOP SYSTEM

 The output have an effect on the input signal, modifying

it to maintain an output signal at the required value.

Comparison Error
element signal

Ref. Correction Controlled

+- Control unit Process
value unit variable

Measuring
Measured value device

44
 CONT…
 Comparison element: 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.
 Control element: decides what action to take when it
receives an error signal. Eg: a signal to operate a switch
or open a valve.
 Correction element: produces a change in the process
to correct or change the controlled condition. Eg: a switch
on a heater to increase the temperature of the process or
a valve which opens and allows more liquid to enter the
process.
 Process element: is what is being controlled. It could be
a room in a house with its temperature being controlled45
or tank of water with its level being controlled.
 Measurement element: it produces a signal related to
the variable condition of the process that is being
controlled. It might be, for example, a switch which is
switched on when a particular position is reached or a
thermocouple which gives an emf related to the
temperature.
Input + Output
Switch Electric fire
Req. Electric A constant
- power
temp. temperature
Deviation
signal
Measuring
devices

Feedback of temperature signal 46

EXAMPLE: SHAFT SPEED CONTROL (CLOSED LOOP SYSTEM)

47
 ELEMENTS OF SHAFT SPEED CONTROL

 Controlled variable: speed of rotation of shaft

 Reference value: voltage set using potentiometer

 Comparison element: Amplifier

 Error signal: difference b/n output and ref. value

 Control unit: Amplifier

 Correction unit: Motor

 Process: rotating shaft

 Measuring device: tachogenerator

48
 SEQUENTIAL CONTROLLERS
 Used when control is such that actions are strictly
ordered in a time or event driven sequence.
 Could be obtained by an electrical circuit with sets of
relays or cam-operated switches which are wired up in
such a way as to give the required sequence.
 Eg: a domestic washing machine
 Operations:-
❑ pre-wash(a wash in cold water): opening a valve to fill water
then closing a valve, switching the drum motor for a specific
time then operating the pump to empty the water from the
drum.
❑ Main wash follows: a wash in warm water a number of times
❑ Spinning: to remove water from the closes.
49
 Cam operated switches are used
 MICROPROCESSOR BASED CONTROLLERS

 Rapidly replacing the mechanical cam operated

controllers and being used in general to carry out control
functions.
 A great variety of programs become feasible.
 Eg: modern washing machines
 The operating sequence is called a program
 The controller is a microprocessor
 The program is not supplied by the mechanical arrangement
but by a software program.

50
 ENGINE MANAGEMENT SYSTEM
 Responsible for managing the ignition and fuelling requirements of the
engine.

FOUR STROKE INTERNAL COMBUSTION ENGINE 51

 Engine speed
Spark timing

Crankshaft position

Spark timing feedback

Air Fuel Mixture Solenoid
Micro
Engine temperature processor

Throttle position
Fuel injection valve
Mass air flow

Basic elements of a microprocessor control system 52

MECHATRONIC SYSTEM
EXAMPLES
COPY MACHINE

54
 It has Analogue and digital circuits, sensors, actuators, and
microprocessors.
 Working
 User places an original in a loading bin and pushes a button
to start the process.
 The original is transported to the platen glass
 A high intensity light source scans the original and transfers
the corresponding image as a charge distribution to a drum.
 Blank piece of paper is retrieved from loading cartridge, and
image is transferred onto the paper with an electrostatic
deposition of ink toner powder that is heated to bond to the
paper.
 A sorting mechanism then delivers the copy to an appropriate
bin.
55
 Control
 Analogue circuits control the lamp, heater, and other
power circuit.
 Digital circuit controls digital display, indicator lights,
buttons, switches forming the user interface.
 Other digital cct include logic ccts and microprocessor
that coordinates all the functions of the machine.
 Sensors
 Optical sensors and micro switches detect the
presence on absence of paper, its proper positioning,
and whether or not door and latches are in proper
position.
 Encoders used to track motor rotation.
 Actuators
 (servo/stepper) load and transport the paper, turn the
drum and index the drum.
56
TODDLER-WALKING ROBOT

57
 Actuators
 Servo Motors
 Sensors
 IR Sensor for obstruction detection
 Bumper Sensor for obstruction detection
 Compass, for orientation detection
 Accelerometer, for tilt detection
 Ultrasonic sensor, for range detection.
 Micro Controller
 BASIC Stamp 2 module

58
 FUTURE OF MECHATRONICS
 Growth in mechatronic systems will be fueled by the growth in
the constituent areas.
 Advancements in traditional disciplines fuel the growth of
mechatronics systems by providing “enabling technologies.”
 For example, the invention of the microprocessor had a profound
effect on the redesign of mechanical systems and design of new
mechatronics systems.
 We should expect continued advancements in cost-effective
microprocessors and microcontrollers, sensor and actuator
development enabled by advancements in applications of
MEMS, adaptive control methodologies and real-time
programming methods, networking and wireless technologies,
mature CAE technologies for advanced system modeling, virtual
prototyping, and testing.
 The continued rapid development in these areas will only
accelerate the pace of smart product development. 59
 The Internet is a technology that, when utilized in combination
with wireless technology, may also lead to new mechatronic
products.
 While developments in automotives provide vivid examples of
mechatronics development, there are numerous examples of
intelligent systems in all walks of life, including smart home
appliances such as dishwashers, vacuum cleaners, microwaves,
and wireless network enabled devices.
 In the area of “human-friendly machines” we can expect
advances in robot-assisted surgery, and implantable sensors and
actuators.
 Other areas that will benefit from mechatronic advances may
include robotics, manufacturing, space technology, and
transportation.
 The future of mechatronics is wide open.
60
~END~

61