MODULE – 1 INTRODUCTION

Topics:- Introduction to Mechatronics system –Types of Design -Mechatronics Design Process- Key Elements .

INTRODUCTION
1.1 MECHATRONICS
Mechatronics is a concept of Japanese origin and can be defined as the application of electronics and
computer technology to control the motions of mechanical systems.

Fig 1: Origin of mechatronics

It is a multidisciplinary approach to product and manufacturing system design. It involves application of
electrical, mechanical, control and computer engineering to develop products, processes and systems
with greater flexibility, ease in redesign and ability of reprogramming. It concurrently includes all these
disciplines.

Fig.2: The field of mechatronics: intersection of

mechanical engineering, electrical engineering, and computer science.

1.2 SYSTEM
A system may be defined as a block box which has an input and an output. System concerned only with
the relationship between the input and output and not on the process going inside the box.

Fig 3: A system example

1.3 MECHATRONIC SYSTEM
 Fig 4: Elements of mechatronics
 Actuators: Solenoids, voice coils, D.C. motors, Stepper motors, Servomotor,
hydraulics, pneumatics.
 Sensors: Switches, Potentiometer, Photo - electrics, Digital encoder, Strain gauge,
Thermocouple, accelerometer etc.
 Input signal conditioning and interfacing: Discrete circuits, Amplifiers, Filters, A/D,D/D.
 Digital control architecture: Logic circuits, Microcontroller, SBC, PLC,
Sequencing and timing, Logic and arithmetic, Control algorithm, Communication.
 Output signal conditioning and interfacing: D/A D/D, Amplifiers, PWM, Power transistor,
Power Op -amps.
 Graphical displays: LEDs, Digital displays, LCD, CRT.
1.4 Application 1: MEASUREMENT SYSTEM
A measurement system can be defined as a black box which is used for making measurements. It has the
input as the quantity being measured and the output as a measured value of that quantity.

Fig 5: A measurement system

 Elements of Measurement Systems:
Measurement system consists of the following three elements.
a) Sensor b) Signal conditioner c) Display System

Fig 6: Elements of measurement system

 Sensor:
A sensor consists of transducer whose function is to convert the one form of energy
into electrical form of energy. A sensor is a sensing element of measurement system that
converts the input quantity being measured into an output signal which is related to the
quantity.
 Signal Conditioner:
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 A signal conditioner receives signal from the sensor and manipulates it into a suitable
condition for display. The signal conditioner performs filtering, amplification or other signal
conditioning on the sensor output.
 Display System:
A display system displays the data (output) from the signal conditioner by analog or
digital. A digital system is a temporary store such as recorder.

1.5 CONTROL SYSTEM

A black box which is used to control output value according to pre-set value.

Fig 7: Elements of a control system

 Open loop control system: If there is no feedback device to compare the actual value with desired one.
No control over its input.

Fig 8: Open loop control system

 Closed loop control system: If there is feedback device to compare the actual value with desired one.

Fig 9: Closed loop control system

 Elements of Closed Loop System: The elements of closed loop control system are

1. Comparison unit

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 2. Control unit

3. Correction unit

4. Process unit

5. Measurement Device

1.6 Example 1: SYSTEM OF CONTROLLING WATER LEVEL

Fig 10: Water level indicator

Controlled variable: Water level in the tank
Reference variable: Initial setting of the float and lever position
Process: The water level in the tank
Measuring device: The floating ball and lever
Comparison Element: The lever
Error signal: Difference between the actual & initial setting of the lever positions
Control Unit: The pivoted lever
Correction Unit: The flap opening or closing the water supply
1.7 KEY ELEMENTS OF MECHATRONICS SYSTEMS

Digital Actuators Digital Sensor

Mechanical
Analogue Actuators systems
Analogue Sensor

Microprocessor for
system control

Fig. 11 Key Elements of Mechatronics Systems

Digital actuators are devices that convert digital signals into mechanical movement or force.
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 They are typically controlled by a computer or microcontroller using digital signals such as Pulse
Width Modulation (PWM) or digital command signals like serial or parallel.

Examples of digital actuators include servo motors, stepper motors, and solenoids. They are
commonly used in robotics, automation, and control systems.

Analog actuators are devices that convert analog signals into mechanical movement or force.

They typically use continuous signals such as voltage or current to control the position, speed, or
force of the actuator. Examples of analog actuators include linear motors, DC motors, and pneumatic
cylinders. They are commonly used in industrial automation, robotics, and control systems, as well as
in various consumer and commercial applications such as automobiles, appliances, and machinery.

Digital sensors are devices that convert a physical or environmental condition into a digital signal.
They typically use analog-to-digital conversion to convert the analog input into a digital output that
can be read and processed by a computer or microcontroller. Examples of digital sensors include
digital cameras, digital microphones, and digital temperature sensors. Digital sensors are commonly
used in a wide range of applications, including robotics, automation, control systems, and consumer
electronics. They are known for their high accuracy, fast response time, and easy digital interfacing
with other devices.

Analog sensors are devices that convert a physical or environmental condition into an analog signal,
such as voltage or current. They are used to measure a wide range of physical phenomena such as
temperature, pressure, light, sound, and motion.

Examples of analog sensors include thermistors, photoresistors, microphones, and accelerometers.

They are commonly used in industrial automation, control systems, robotics, and other applications
where precise measurements are needed. They can be interfaced with analog-to-digital converters to
interface with digital systems.

Analog sensors are known for their ability to provide a continuous signal output, allowing for more
nuanced measurements compared to digital sensors.
2.1 TYPES OF DESIGN PROCESS
There are two ways of design process available.

1. Traditional design process

a. Adaptive Design: In most cases, the designer’s work is concerned with adaptation of
existing designs. This type of design needs no special knowledge or skill and can be
attempted by designers of ordinary technical training. The designer only makes minor
alternation or modification in the existing designs of the product.

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 b. Development Design: This type of design needs considerable scientific training and design
ability in order to modify the existing designs into a new idea by adopting a new material or
different method of manufacture. In this case, though the designer starts from the existing
design, but the final product may differ quite markedly from the original product.

c. New Design: This type of design needs lot of research, technical ability and creative thinking.
Only those designers who have personal qualities of a sufficiently high order can take up the
work of a new design.

The designs, depending upon the methods used, may be classified as follows:

i) Rational design. This type of design depends upon mathematical formulae of principle of

mechanics.

(ii) Empirical design. This type of design depends upon empirical formulae based on the practice
and past experience.

(iii) Industrial design. This type of design depends upon the production aspects to manufacture

any machine component in the industry.

(iv) Optimum design. It is the best design for the given objective function under the specified

constraints. It may be achieved by minimising the undesirable effects.

(v) System design. It is the design of any complex mechanical system like a motor car.

(vi) Element design. It is the design of any element of the mechanical system like piston,

crankshaft, connecting rod, etc.

(vii) Computer aided design. This type of design depends upon the use of computer systems to

assist in the creation, modification, analysis and optimisation of a design.

2.1.1 Traditional design has been carried in the following number of stages

(a) The Need:

The design process starts with the need of a customer.
 By adequate market research and knowledge, the potential needs of a customer can
be clearly identified.
 In some cases, company may create a market need but failures are more in this area.
 Hence, market research technology is necessary.
(b) Analysis of the Problem:

 This is the first stage and also the critical stage in the design process.
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  After knowing the customer need, analysis should be done to know the true nature
of the problem.
 To define the problem accurately, analysis should be done careful.
(c) Preparation of a Specification:
 The second stage of the mechatronic process involves in the preparation of a
specification
 The specification must be given to understand the requirements and the functions to
bemet.
 The specification gives mass dimensions, types, accuracy, power requirements,
load, praying environments, velocity, speed, life etc.
(d) Conceptualization:

 The possible solution should be generated for each of the functions required
 It is generated by verifying the old problems or some newly developed techniques
may be used.
(e)Optimization:

 This stage involves in a selection of a best solution for the problem

 Optimization is defined as a technique in which a best solution is selected among a
group of solutions to solve a problem.
 The various possible solutions are evaluated and the most suitable solution is

selected.
(f) Detail Design
 Once optimizing a solution is completed, the detail design of that solution is
developed.
 This may require a production of proto type etc.

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  Mechanical layout is to be made whether physically all component can
be accommodated.
 Also whether components are accessible for replacement / maintenance are to
bechecked.
(h)Production of working Drawings:

 The selected design or solution is then translated into working drawings,

circuitdiagrams, etc. So that the item can be made.
 Drawings also include the manufacturing tolerances for each component.
2. MECHATRONICS DESIGN PROCESS:
With traditional design, the approach was for the mechanical engineer to design the mechanical elements,
then the control engineer to come along and design the control system. This gives what might be termed a
sequential approach to the design.
However, the basis of the mechatronics approach is considered to lie in the concurrent inclusion of the
disciplines of mechanical engineering, electronics, computer technology and control engineering in the
approach to design.
The inherent concurrency of this approach depends very much on system modelling and then simulation
of how the model reacts to inputs and hence how the actual system might react to inputs.

The mechatronic design process consists of three phases:

1. Modelling and Simulation,
2. Prototyping
3. Deployment.
All modelling, whether based on first principles (basic equations or the more detailed physics,
should be modular in structure.
A first principle model is a simple model that captures some of the fundamental behaviour of a subsystem.
A detailed model is an extension of the first principle model providing more function and
accuracy than the first-level model. Complex models may be created by connecting the modules, or blocks,
together.
DIFFERENCE BETWEEN TRADITIONAL AND MECHATRONIC APPROACHES
Engineering design is a complex process which involves interaction between many skills and
discipline. In traditional design, the components are designed through mechanical, hydraulic or
pneumatic components and principles. But in mechatronics approach, mechanical, electronics,
computer technology and control engineering principles are included to design a system.
For example design of weighing scale might be considered only in terms of the compression of
springs and a mechanism used to convert the motion of spring into rotation of shaft and hence
movements of a pointer across a scale. In this design measurement of weight is depended on the
position of weight on the scale. If we want to overcome foresaid problem, other possibilities
can be considered. In mechatronics design, the spring might be replaced by load cells with strain
gauges and output from them used with a microprocessor to provide a digital readout of the
weight on an LED display. This scale might be mechanically simpler, involving fewer
components and moving parts. But the software is somewhat complex.
Similarly the traditional design of the temperature control for a central AC system involves a
bimetallic thermostat in a closed loop control system. The basic principle behind this system
is that the bending of the bimetallic strip changes as the temperature change and is used
to operate an ON/OFF switch for the temperature control of the AC system
The same system can be modified by mechatronics approach. This system uses a microprocessor
controlled thermo couple as the sensor. Such a system has may advantages over traditional
system. The bimetallic thermostat is less sensitive compared to the thermo diode. Therefore
the temperature is not accurately controlled. Also it is not suitable for having different
temperature at different time of the day because it is very difficult to achieve.
But the microprocessor controlled thermo diode system can overcome fore said difficulties and
is giving precision and programmed control. This system is much more flexible. This
improvement in flexibility is a common characteristic of the mechatronics system when
compared with traditional system.