08-08-2023

DESIGN OF MECHATRONIC SYSTEMS

Historical development of industrial systems (from Mechanical to Mechatronic).
Basic building blocks of mechatronic systems.

Presented by
Prof Vikram Vyawahare , HOD Mechatronics Engineering

OUTLINE OF PRESENTATION
• Course Outcomes
• Syllabus Overview
• Historical development of Industrial Systems
• Origin of the word Mechatronics
• Mechatronics Design Philosophy
• Components of Mechatronic systems
• Examples of Mechatronic Products

Presented by Prof. Vikram Vyawahare 1

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COURSE OUTCOMES
• Outcomes: Learner will be able to...
• Explain Design Process , structure, elements and application of Mechatronics
• Modelling and simulation of Mechatronic system including system identification
• Implement Servo control and controller tuning.
• Actuator selection and drive train design for motion control applications
• Motion control programming for industrial applications
• Indigenously design and develop a mechatronic system.

MODULE 1: MECHATRONIC
DESIGN AND APPLICATIONS
7 Hrs

• Historical development of industrial systems (from Mechanical to

Mechatronic).
• Basic building blocks of mechatronic systems. Key Elements of Mechatronics:
Information Systems, Mechanical Systems, Electrical Systems, Computer
Systems, Sensors and Actuators, Real Time Interfacing.
• Generalized Mechatronics Design Process: Phase I Modelling and Simulation,
Phase II Prototyping, Phase III Deployment/Lifecycle
• Performance characteristics of sensors and transducers. Selection criteria for
sensors and actuators, interfacing of sensors and actuators. Mechatronics in
home, office and industrial automation.

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MODULE 2 : MODELLING AND

SIMULATION
• Why Bond graph for mechatronics? Review of Bond graph modelling. 6 Hrs

• 2.1 Bond graph modelling of Actuators Mechanisms and Linkages, (Example

of belt drive) Electrical Actuators (Example of PM DC Motors,), Hydraulic /
Pneumatic Actuators (Example of double acting pneumatic actuator)
• 2.2 Bond graph modelling of Sensors : Activated bond, Position , Velocity,
• Acceleration, Force and Pressure sensor bond graph modelling
• 2.3 Bond graph modelling of Circuits (Example of H Bridge Circuit,
Operational Amplifier Inverting and non-Inverting )
• 2.4 Introduction to Simulation

MODULE 3 : INTRODUCTION TO
SYSTEM IDENTIFICATION
4 Hrs
• System Theory: Open systems, Input, Disturbance, State, Output. Basic
Problems in system theory, Mathematical models, properties, Convolution
integral, System Identification procedure.
• System response methods : Impulse Response Model Representation, Transfer
function model representation , direct impulse response identification , Direct
Step Response Identification,

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MODULE 4 : SERVO CONTROL OF

ACTUATORS
• 4.1 DC Servo: Types of DC Servo, DC Servo Motors in Open and Closed Loop 8 Hrs
Velocity Control, DC Servo Motors in Closed Loop Position Control.
• 4.2 Stepping Servo: Stepping motor for position control applications
• 4.3 AC Servo Motors ,Rotor ,Stator, Sinusoidal Commutation Torque Generation with
Sinusoidal Commutation Six-Step Commutation of AC Servo Motors Motor Phasing
with Encoders and Hall Sensors. AC Induction Motors , Stator , Rotor , Motor
Operation , Constant Speed Operation Directly Across-the-Line, Variable Speed
Operation with a VFD.AC Drives : Drive Electronics , Converter and DC Link , Inverter,
Conduction and PWM switching.
• AC Servo Basic Control Structures: Cascaded Velocity and Position Loops ,Single-
Loop PID Position Control , Cascaded Loops with Feedforward Control , Inner Loop ,
Inner Loop for AC Induction Motors ,Inner Loop for AC Servo Motors
• AC Servo Tuning : Tuning a PI Controller , Tuning a PID Position Controller
• 4.4 Electrohydraulic Servo Motors: Mechanically controlled servo, Electro hydraulic
servo valves, Hydraulic servo motors

MODULE 5
• 5.1 Motion Profile, Kinematics: Basic Concepts, Common Motion Profiles: Trapezoidal 8 Hrs
Velocity Profile, S-curve Velocity Profile
• Multiaxis Motion: Slew Motion, Interpolated Motion, Problems.
• 5.2 Drive-Train Design: Inertia and Torque Reflection, Gearbox Ratio Reflected Inertia
,Reflected Torque , Efficiency Total Inertia, Inertia Ratio, Targeted Practical Inertia Ratio.
Transmission Mechanisms, Load and Inertia Reflection through Transmission Mechanisms
,Pulley-and-Belt , Lead Screw ,Rack-and-Pinion Drive , Belt-Drive for Linear Motion,
Conveyor Torque Required for the Motion , Acceleration (Peak) Torque, Running Torque
,Deceleration Torque , Continuous (RMS) Torque
• 5.3 Comparison and selection of Servo Motors: Theory and Performance Criteria,
Comparison of result and design procedure
• AC Servo Motor Selection: Torque–Speed Curves for AC Servomotors Motor Sizing
Process , Motor Selection for Direct Drive ,Motor and Transmission Selection , Gearboxes
Planetary Servo Gearheads , Worm Gear Speed Reducers , Servo Motor and Gearhead
Selection , AC Induction Motor and Gearbox Selection
• Problems on Motor, Gearbox, and Transmission Mechanism Selection for industrial
applications.

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MODULE 6
• Motion Control : Components of motion control system, Motion Controller 6 Hrs
Programming and Applications , Move Modes: Linear Moves , Circular Moves
, Contour Moves
• Programming: Motion Programs, PLC Functionality, Single-Axis Motion ,
Jogging ,Homing Multiaxis Motion: Multiple Motors Driving One Axis,
Coordinated Motion of Two or More Axes , Following Using Master/Slave
Synchronization : Electronic Gearing, Electronic Camming, Ratio Following,
Time-base Control. Motion control algorithm development for industrial
applications

HISTORICAL
DEVELOPMENT
OF INDUSTRIAL
SYSTEMS

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PURE MECHANICAL SYSTEMS<1860

• Steam Engines

Atmospheric engine was invented by Thomas Newcomen in 1712

PURE MECHANICAL SYSTEMS<1860

• Pumps

https://tfpumps.com/history-of-
pumps/

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ELECTRICITY
• Dynamo

The first commutated dynamo was built in

1832 by Hippolyte Pixii, a French instrument
maker

PURE MECHANICAL SYSTEMS<1860

• IC Engines

• In 1864, Nicolaus Otto patented the first atmospheric gas engine.

https://en.wikipedia.org/wiki/History_of_the_internal_combustion_engine

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MECHANICAL SYSTEMS WITH

ELECTRICAL DRIVES - 1920
• RELAYS
• In 1809 Samuel Thomas von
Sömmerring designed an
electrolytic relay as part of his
electro-chemical telegraph

MECHANICAL SYSTEMS WITH

ELECTRICAL DRIVES - 1920
• Amplifiers
• The first practical prominent device that could amplify was the triode
vacuum tube, invented in 1906 by Lee De Forest, which led to the first
amplifiers around 1912.

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MECHANICAL SYSTEMS WITH

AUTOMATIC CONTROL 1935
• Pneumatic PID Controller 1930

TRANSISTOR
• Transistor 1947 ,

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MECHANICAL SYSTEMS WITH

ELECTRONIC ANALOG CONTROL -
1955
• Electronic analog control
• Sequential control

DIGITAL COMPUTER
• Atanasoff Barry1939 to 1942 MOSFET MOSFET 1959 Microprocessor 1971

• MIT Whirlwind 1951

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MECHANICAL SYSTEMS WITH

DIGITAL CONTROL
• Digital continuous control
• Digital sequential control

• first commercial numerically controlled lathe, developed by Dr. F. W.

Cunningham. Arma's first automated lathe was made in 1948, and
announced in 1950.

MICRO CONTROLLER
• CPU RAM ROM IO and timer on single chip

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MECHATRONIC SYSTEMS 1985

• Integration of mechanical, electronic and software

ORIGIN OF WORD
MECHATRONICS
• The word mechatronics originated in Japanese-
English and was created by Tetsuro Mori, an
engineer of Yaskawa Electric Corporation in 1969.
• The word mechatronics was registered as trademark
by the company in Japan with the registration
number of "46-32714" in 1971. The company later
released the right to use the word to the public, and
the word began being used globally.

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WHAT IS MECHATRONICS ?
• Mechatronics is the
synergetic integration of
different engineering
domains such as mechanics,
electronics and information
technology to create new
products and innovative
solutions.
• Success stories
– CD player,
– Adaptive automatic
transmission ,
– Auto-focus camera
– etc

MECHATRONICS: DESIGN
PHILOSOPHY
• Now mechatronics refers to a design philosophy.
• Mechatronics is a methodology used for optimal
design of electromechanical products.
• The mechatronic design methodology is based on
concurrent instead of sequential approach to
design, resulting in products with better synergy.

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MECHATRONIC SYSTEMS

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EXAMPLE MECHATRONIC SYSTEM

EXAMPLE MECHATRONIC SYSTEM

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EXAMPLE MECHATRONIC SYSTEM

32

COMPONENTS OF A
MECHATRONIC SYSTEM
Display Keypad

Control
Computer
Digital Output Digital Input

Mechanical Subsystem
Signal
Interface Electronics subsystem Conditioning
Electronics Control Software and
Hardware

Machine Sensors
Actuators /Robot

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MECHANICAL SYSTEM
•System model , Dynamic Response
INPUT SIGNAL
ACTUATORS SENSORS
CONDITIONING
•Solenoid, •Switches AND INTERFACING
• voice coils •Potentiometer
•DC Motors •Thermocouple
•Stepper motors •Digital encoder •Discrete
•Servo motors •Strain gauge circuits
•Accelerometer •Amplifiers
•Hydraulics, •etc
pneumatics •Filters
•A/D , D/A

OUTPUT SIGNAL DIGITAL CONTROL

GRAPHICAL CONDITIONING ARCHITECTURE
DISPLAY AND INTERFACING •Sequencing and
•Logic circuits
•LED •Amplifiers timing
•Microcontroll
•Digital display •PWM •Logic and arithmetic
er •Control algorithm
•LCD •Power transistors
•CRT
•PLC •Communication
•Power Op Amps

EXAMPLE MECHATRONIC
PRODUCTS

Presented by Prof. Vikram Vyawahare 17

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MECHATRONICS IN
MANUFACTURING

Presented by Prof. Vikram Vyawahare 18