MECHATRONICS

DEVELOPMENT OF MECHATRONICS
 UNIT I SENSORS AND
ACTUATORS

MECHATRONICS
UNIT II SIGNAL
CONDITIONING CIRCUITS
AND PLC

UNIT III FUNDAMENTALS

OF IoT AND EMBEDDED
SYSTEMS

UNIT IV CONTROLLERS

UNIT V MECHATRONICS
AND IoT CASE STUDIES
INTRODUCTION
Mechatronics -
Synergistic
combination of
Mechanical,
Electronic,
Computer and
Control systems.

Eg : Autofocus
camera, Automated
production line
MECHATRONICS SYSTEM
• Integrates various technologies involving,
sensors, measurement systems, drives,
actuation system, microcontrollers and
software engineering.
• Embedded systems – microprocessor based
system to control a range of functions.
• Eg : Mobile phones, Printers, Scanners
Television . . .
Examples of Mechatronics systems

Computer disk drive

Office equipments
NEED FOR MECHATRONICS
Product
Market Range Production
Condition Rate

Process
Quality &
Capability Mechatronics Consistency

Better
Flexibility
Control Optimization
 Classification of Mechatronics
• Integrates electrical signal with
Primary mechanical control
Level • Fluid valve, relay switches

• Integrates microelectronics into

Secondary electrically controlled devices
Level • Cassette tape player

• Advanced control strategy using

Tertiary
microprocessor and specific integrated
Level circuits

Quaternary • Artificial neural network, Fuzzy logic

Level • Fault detection and Isolation
EMERGENCE OF MECHATRONICS ENGINEERING

Type Examples
Transducers and Ultrasonic receiver,
measuring instrument Electronic scale
Processing Machines Machining centres,
Bonding machines
Industrial Handlers Robots
Drive Mechanisms CD players, Printers
Interface device Keyboard, Mouse
 SYSTEM & MODELLING
• Block diagram which has an input and an
output with relationship between the output
and the input. – SYSTEM
• Representation of mathematical relationship
between input and output. - MODELLING
Input Output
Force Spring Extension

Input Output
CD deck Amplifier Loudspeaker Sound
CD
Electrical Bigger Electrical
Signals Signals
 CONTROL SYSTEMS
• Control some variable to some particular
value.
• Control the sequence of events.
• Control whether the event occur or not.

The required Hand moving towards

hand position Picking up the pencil
the pencil

Feed back data about actual position

 TYPES OF CONTROL SYSTEMS
• Open loop system
• Closed loop system
Input Switch Air cooler Output
Controller
Switch Temperature
on/off Hand activated Electric Power Change
Comparison
element
Input Controller Switch Air cooler Output
+/-
Switch Temperature
on/off Hand activated Electric Power Change

Feedback of temperature-related signal

 ELEMENTS OF CLOSED-LOOP SYSTEM
• Comparison element
• Control element
• Correction element
• Process element
• Measurement element
Comparison
element
Reference Correction Process Output
+/- Control
Value Unit Unit Controlled
Unit
Variable

Measured Value Measuring

Device
 SENSORS & TRANSDUCERS
• An element which produces signal relating to
the quantity being measured - Sensor.
• An element when subjected to some physical
change experiences a related change which
converts a specified measurement into a
usable output - Transducer.
• Every transducer is also(or has) a sensor but
every sensor need not be a transducer.
 Measurement system

Characteristics of
measurement system

Static – independent on time Dynamic – dependent on time

Accuracy, Resolution, Precision, Response time, Time Constant,

Sensitivity Rising time, Settling time
 TERMINOLOGY USED IN SENSORS
• Range • Accuracy
Defines the maximum and Extent to which the value
minimum value indicated by system might be
wrong (±)
• Span • Sensitivity
Defines the difference relationship indicating how
between maximum and much output there is per unit
minimum value input
• Error • Repeatability
Difference between the Ability to give same output
result of measurement and for repeated application of
true value of quantity same input value.
TERMINOLOGY USED IN SENSORS
• Hysteresis error
Maximum difference in • Dead band
output for increasing For a range of input
and decreasing values value there is no
• Non-linearity error output
Maximum difference • Resolution
from the straight line Small change in input
• Stability value that will produce
Ability to give same a observable change in
output for constant output
input over a period of
time (DRIFT)
 STATIC AND DYNAMIC CHARACTERISTICS

• Response time
• Time Constant
• Rising time
• Settling time

Response of
thermometer when
dipped in hot water
 TYPES OF SENSORS
• Displacement, position, proximity
• Velocity and motion
• Fluid gauge
• Liquid flow
• Liquid level
• Temperature
 Displacement Sensor
• Potentiometers
• Strain gauge
• Capacitive Sensor
• Eddy Current Proximity Sensor
• Hall effect Sensor

• LVDT (Linear Variable Differential Transformer)

 Potentiometer sensor
• Converts position information into variable
voltage through a resistor

Used in machine tool controllers, elevators,

injection moulding machines
 Strain Gauge Sensor
• Fractional change in length – Strain
• Strain gauge is a strip of semiconductor material can
be stick on surface like a postal stamp.
• Fractional change in resistance is measured.
• Based on whetstone bridge principle.
• Measured as micro or milli strain.
• Vibration and deflection measurement
 Capacitive sensor

• It is a non contact type sensor. (permittivity)

• Used to measure displacement in mm or m.
Capacitance
Application
= Relative Permittivity
= Permittivity of air
Metrology application &
Assembly line testing
Differential Transformer
 Eddy Current Sensor
• Used to detect non-magnetic but conductive
materials.
• Coil, Oscillator, Detector, Triggering circuit.
• Impedance of coil changes along with amplitude of
current.
• Inexpensive, highly reliable , high sensitivity for small
changes
 Hall effect Sensor
• When charge particle
passes through a magnetic
field, forces act on the
particles and beam is
deflected.
• This charge separation
generates a potential
difference which is measure
of current.
• Non contact operation and
good immunity to
environment contaminants.
• Industrial automations. Discovered by E.R. Hall in 1879
 Temperature Sensor
• Temperature measurement
• Contact measurement
• Non contact measurement
• Temperature change conveys a state of change
in electrical resistance.
• Examples
 Bimetallic strip
 Thermocouples
 Thermistors.
 Bimetallic strip
• Different metal strip bonded together.
• Different co-efficient of expansion.
• The deformation may be used as temperature
controlled switch
 Thermistors
• Small pieces of material – sintered metal
oxides – semiconductors.
• Decrease in resistance with in temperature.
Resistance Temperature Relation ship

• Advantages – Very small, rapid response

• Disadvantage - Non-linearity
 Thermocouples
• Dissimilar metals joined together.
• Potential difference occurs at junction –
depends on the temperature difference and
metals used – Thomas Seeback effect
Ref Materials Range (°C) (V/°C)
B Platinum/rhodium 0-1800 3
E Chromel/constantan -200 to 1000 63
J Iron/constantan -200 to 900 53
K Chrome/alumel -200 to 1300 41
N Nirosil/nisil -200 to 1300 28
T Copper/constantan -200 to 400 43
 Light Sensors
• Photo Diodes – semiconductor devices –
increase in reverse current proportional to the
intensity of light – rapid response to light
• Photo Transistor – light sensitive collector – (p-
n junction)
• Photo resistors – resistance depends on
intensity of light – cadmium sulphide response
to 515 nm wave length of light.
• Eg . CCD (Charge Coupled Device)
 Light Sensors

Photo Diode Photo Resistor

Silicon – converts Cadmium Sulphide –

incident light into electric Response to wavelength <
current 515 nm

Fast response to light – Array of sensors used –

used as variable CCD (charge coupled
resistance device device)
 Assignment-1 Submission Date:
PART A
1.Define mechatronics.
2.Define system with block diagram.
3.List the key elements of mechatronics system.
4.Differentiate sensor and transducer.
5.Explain dynamics characteristics of a measurement
system.
6.Differentiate displacement sensor and position
sensor.
7.Compare accuracy and precision.
PART B
1. Describe the classification of mechatronics. List
advantages and disadvantages of mechatronics
system
 Assignment - 2 Submission Date:
PART A
1.What is LVDT? List its advantages.
2. Differentiate between range and span.
3. What is hysteresis error?
4. Define Resolution.
5. Define Open loop and closed loop systems.
6. Classify sensors based on its applications.
7. Define capacitive transducer.
PART B
1. With neat diagram explain the working principle
of resistance potentiometer.
 Submission Date:
Assignment - 3
PART B
1. Explain the factors to be considered for the selection of
sensor with any two examples?
2. With neat sketch explain about “Automatic Control of
water level”.
3. Explain the following
 Temperature sensor
 LVDT
 Capacitance sensor
 Hall effect sensor
 Eddy current sensor
 Light sensors
PROGRAMMABLE LOGIC
CONTROLLER
PROGRAMMABLE LOGIC CONTROLLER
• Digital electronic device
• To store instruction
• To implements functions (logic, timing,
arithmetic)
• To control machines
• Introduced to replace hard wired relay and
timer control system.
• Similar to computers - designed to withstand
vibration, temperature humidity and noise
 Components of PLC
• Input module
– Real time status of variable
• CPU (Central Processing Unit)
• Memory
• Programming Devices
– Schematic representation of hardware and
process controller called as ladder diagram
• Output Module
 Basic Structure - PLC

1. Sensing Input signal 4. Programming device or PC

2. Input section 5. Output Section
3. CPU – processing 6. Output device
 PLC – Internal Architecture
• Data Bus
• Address Bus
• Control Bus
• I/O System Bus

• Arithmetic and logic Unit

• Control Unit
• Memory Unit • Input – digital or analog
• Output - Motors, valves
• Voltage 5V, 24V, 110V
 Input /Output Processing
Continuously running the program and updating
input signals in loop is termed as cycle.
1.Continuous updating
• Built in delay of 3 ms for each input to
avoid error in counting.
• Outputs are latched their status until next
updating.
2. Mass input / output copying
• To avoid time delay RAM is used
PLC - Ladder Programming
Input 1 Output A
Input as contact
not closed until
input Input 2 Input 3 Output B

Input as contact
which are closed Input 4 Output C
until input

Output Input 5

Special Instruction END

PLC LOGIC
 MNEMONICS
• Ladder language to be transformed into
program/instruction set for entering into
computer.
• Instructions lists are called as “Mnemonics”.
• Different PLC manufactures use different codes.
• International standard – ( IEC1131-3 )
(International Electro technical Communication)
 Instruction codes
MNEMONICS Operation Ladder Diagram
LD Load operand into Start a rung with open
register contacts
LDI Load negative operand Start a rung with closed
into result register contacts
AND Boolean AND A series element with open
contacts
ANI Boolean AND with A series elements with
negative operand closed contacts
OR Boolean OR A parallel element with open
contacts
ORI Boolean OR with A parallel element with
negative operand closed contacts
OUT Store result register An output from a rung
into operand
MNEMONICS
 Latching – Internal relays
Input 1 Input 2 Output
• Self-maintaining circuit
after being energised.
Output • Maintain that state until
another input received
MOTOR
CONTROL
START STOP
RELAY
• Control of a motor.
• STOP switch not depend
on PLC for safety
purpose
MOTOR
 Internal relays

An output controlled by two Starting of multiple outputs

inputs arrangement
 Timers
• Open or close of contacts after present time.
• Delay block in a rung
• Generally with delay-on timer (TON)

Timed
Sequence
 Timers

On/Off cyclic timer

Cascaded timer

Delay-off timer
 Counters
• Used to count number of contact operations.
• Intermediate block in the rung
• Down-counter :- Counts down from the preset
value to zero.
• Up-counter:- Counts up to preset value. When
set value reached counter contact changes
state.
 Data Handling
• Moving of data from one memory to another
• Comparison of magnitude of data
• Arithmetic operations
• Data Conversion.
Problem No- 1
Problem No- 2
Problem No- 3
Problem No- 4
 Actuators
• Actuators are the muscles of robots
• Sensors and transducer produce input where
as Actuators provide the output in
Mechatronics system.
• Actuators are energy conversion device
 Types of Actuators
Actuators

Hydraulic Electric Pneumatic

AC motor DC motor

Synchronous Induction Brushed Brushless

 DC Motors
• A DC motor is a device that converts direct
current (electrical energy) into rotation of an
element
Torque
T = NBbLi
Where
i – current
N – number of conductors
B – magnetic flux density
b – breath of coil
L – length of armature conductor
• Advantages of brushed DC motor:
• The design of the brushed DC motor is quite simple
• Controlling the speed of a Brush DC Motor is easy
• Very cost effective

• Disadvantages of brushed DC motor:

• High maintenance
• Performance decreases with dust particles
• Less reliable in control at lower speeds
• The brushes wear off with usage
 Brushless DC Motors
• Rotor - ceramic
permanent magnet
types
• Stator - windings with
control electronics.
• Replacement of
commutator and
brushes, energize the
stator sequentially
Advantages of brushless DC motor:
• More precise due to computer control
• No sparking due to absence of brushes
• Less electrical noise , No brushes to wear out
• Electromagnets are situated on the stator - easy to cool
• Operating speeds > 10,000 rpm
• Responsiveness and quick acceleration due to low rotor
inertia
Disadvantages of brushless DC motor:
• Higher initial cost
• Complex due to presence of computer controller
• Brushless DC motor also requires additional system wiring
in order to power the electronic commutation circuitry
 AC motor
• Similar to DC motor – but the rotor is
permanent magnet.
• Flux generated by AC current, rotor follows it
and rotates
Classification
• Single phase
• Poly phase

• Induction motor
• Synchronous motor
 Induction Motor
• Stator connected
with power supply.
• Single phase or
three phase motor.
• Rotating magnetic
field causes forces
– which results in Silp occurs when rotor lags behind
torque on rotor. the rotating magnetic field ( rotor
velocity not matched velocity of
magnetic field)
 Synchronous Motor
• 3 phase system – stator winding is divided in
three parts.
• The magnetic field rotates at a constant speed
based on the frequency of current in AC
signal.
• Have low starting torque.
• Overcome slipping –
uniform speed with varying
loads.
• Cannot started as such.
• Used for applications with
infrequent starts
S.No Synchronous Motor Induction Motor
1 Construction is Construction is simpler
complicated
2 Not self starting Self starting
3 Separate DC source is Rotor gets excited by
required for rotor induced e.m.f. So separate
excitation soucre is not necessary
4 The speed is always The speed is always less than
synchronous irrespective synchronous but synchronous
of speed
5 Speed control is not Speed control possible
possible though difficult
 Stepper Motors
• Special type of DC motor – an incremental
motion machine.
• Rotate in both directions
• Move in precise angular increments
• Controlled with digital circuits
• Less than 1 HP – used only in low-power
position control applications.
 Stepper motor
• Stator having multi-pole, multi-phase winding,
rotor has no winding.
• Number of poles depends upon the required
angular change per unit pulse.
• Rotor follows the axis of the air-gap magnetic
field in coincidence with the input pulse.
 Basic Construction
STATOR
Placed around the edge of the rotor.
Electromagnets that can be switched on
and off individually.

ROTOR
Made from two discs placed together so we
get a series of alternating pulses
Operation & Types of Stepper motor

1. Variable reluctance stepper motor

2. Permanent magnet stepper motor
3. Hybrid stepper motor
 Variable reluctance Stepper Motor

• Toothed and non-magnetic rotor.

• Greater resolution as more teeth are added.
• Normally have three or five stator windings
that energized one at a time.
• When winding energised,
current flows and magnetic
poles are created, which
attracts the metal teetn of
the rotor
 Permanent magnet stepper motor
• Permanent magnet poles in rotor.
• Greater resolution as pole pairs increase
or “additional phases”.
• Magnetised motor provide greater flux
and torque than variable reluctance
• Back EMF of rotor – limits
the maximum speed
 Hybrid Stepper Motor
• Has the characteristics of both permanent
magnet and variable reluctance.
• Better performance – step resolution, torque
and speed
• High cost compared to
permanent magnet type.
Comparison of stepper motors
 Stepper Motor Specification and applications

• Pull in torque • Industrial Machines

• Step angle • Security
• Maximum frequency • Medical appliances
• Pull out torque • Consumer Electronics
• Detent torque
• Angular speed
 SERVO motor
• A servo is a device, electrical, mechanical or
electro mechanical, that upon receipt of a
stimulus or input, will employ feedback for
velocity and/or position control, creating a closed
loop.
• The error-detecting device determines when the
regulated quantity is different from the reference
quantity.
• The motors which respond to the error signal
abruptly and accelerate the load quickly are
called the servo-motors
Types of Servo Motors
Servo
Motor

AC Servo DC Servo
Motor Motor

Armature Field
control Control
 Construction of SERVO motor
• It has construction as same as dc motor. It is consist
of stator and rotor and controlling parts.
• It has feedback generator for generating feedback
for controlling the speed & torque.
• It has two ports one for dc supply and other for
controlled dc supply.
Working principle – DC servo motor
 Working principle of DC servomotor:
• In DC operation, servomotors are usually responds to
error signal abruptly and accelerate the load quickly.
A DC servo motor is actually an assembly of four
separate components, namely:
1. DC motor
2. Gear assembly
3. Position-sensing device
4. Control circuit.