ME407 Mechatronic S: Sukesh O P Assistant Professor Dept. of Mechanical Engineering Jecc

SUKESH O P/ APME/ME407- MR- 1
2018
ME407
MECHATRONIC
S
SUKESH O P
Assistant Professor
Dept. of Mechanical Engineering
JECC
10/16/1 SUKESH O P/ APME/ME407- MR-

2018
8
ME407
2
MECHATRONICS
 Course Objectives:
 To introduce the features of various sensors used in CNC machines and
robots
 To study the fabrication and functioning of MEMS pressure and inertial
sensors
 To enable development of hydraulic/pneumatic circuit and PLC
programs for simple applications
SUKESH O P/ APME/ME407- MR- 10/16/18

2018
ME407
3
MECHATRONICS
Expected outcome:
The students will be able to
i. Know the mechanical systems used in mechatronics ii. Integrate
mechanical, electronics, control and computer engineering in the
design of mechatronics systems

2018
ME407
4
MECHATRONICS
Expected outcome:
The students will be able to
i. Know the mechanical systems used in mechatronics ii. Integrate
mechanical, electronics, control and computer engineering in the
design of mechatronics systems

2018
SYLLABU
5
S
 Introduction to Mechatronics, sensors, Actuators, Micro Electro
Mechanical Systems (MEMS), Mechatronics in Computer Numerical
Control (CNC) machines, Mechatronics in Robotics-Electrical drives,
Force and tactile sensors, Image processing techniques, Case studies
of Mechatronics systems.

2018
MODULE-
6
II
 Actuators: Hydraulic and Pneumatic actuators - Directional control
valves, pressure control valves, process control valves. Rotary
actuators. Development of simple hydraulic and pneumatic circuits
using standard Symbols.

2018
MODULE-
7
II
Actuators: Hydraulic and Pneumatic actuators

2018
WHAT IS AN
8
ACTUATOR?
 Actuators are devices used to produce action or motion.
 Input(mainly electrical signal , air, fluids)
 Electrical signal can be low power or high power.
 Actuators output can be position or rate i.e. linear displacement or
velocity.
 Actuation can be from few microns to few meters

2018
FLOWDIAGRAM OF
9
ACTUATO
AN
R

2018
TYPES OF
10
ACTUATORS
 Hydraulic Actuators
 Pneumatic actuators
 Mechanical Actuators
 Electrical Actuators
 Linear actuator: solenoid, Hydraulic/Pneumatic.

 Rotary actuator: motor, Hydraulic/Pneumatic.

2018
 Devices which can be considered to be motion converters in that
they transform motion from one form to some other required
form.
 Eg: Transform linear motion into rotational motion and vice versa.
 Mechanical elements can include the use of linkages, cams, gears,
rack-and-pinion, chains, belt drives, etc.
 Eg: rack-and-pinion can be used to convert rotational motion to linear
motion.
 Many of the actions which previously were obtained by the use of
mechanism are, however, often nowadays being obtained, as a
result of a mechatronics approach by the use of microprocessor
systems.
SUKESH O P/ APME/ME407- MR-
2018
 Mechanisms still, however, have a role in mechatronics systems.
For example, the mechatronics system in use in an automatic
camera for adjusting the aperture for correct exposures involves a
mechanism for adjusting the size of diaphragm.
 Others function:
 Force amplification – given by levers.
 Change of speed – given by gears.
 Transfer of rotation about one axis to
 rotation about another – timing belt.
The term kinematics is used for the study of motion without
regard to forces. When we consider just the motions without any
consideration of the forces or energy involved then we are
carrying out a kinematic
SUKESH Oanalysis of the
P/ APME/ME407- MR-mechanism.
2018
resolved into components components rotating about along one or
mSoUrKeEoHS ftOheP/3APMEMoRn2-e10o8rmore of the axes.
axes.
Translation motion Rotational motion
Movement which can be Rotation

Rotation which
which has
be
resolved into components has
components rotating about
along one or more of the one or more of the axes.
2018
2018
 Each part of a mechanism which has motion relative to
some part is termed a link.
other
 A rigid body which has two or more points of attachment to other
links is termed nodes.
 Each link is capable of moving relative to its neighboring links.
 A joint is a connection between the connected links at their nodes
and which allows some motion between the connected links.
 Levers, cranks, connecting rods and pistons, sliders, pulleys, belts
and shafts are all examples of links.
(a) with two SUb( K)EwSHhtiOht Pr/eAePnModEeM

/ sE40 (c) with four
nodes nodes
 A sequence of joints and links is Fixed frame
known as kinematic chain.
 For a kinematic chain to transmit
motion, one link must be fixed.
Movement of one link will then Slide
produce predictable relative
movements of the others. r Connecting
 It is possible to obtain from one rod
kinematic chain a number of
different mechanisms by having a
different link as the fixed one.
 The design of many mechanisms
Crankshaft
are based on two basic forms of
kinematic chains, the four-bar
chain and the slider-crank chain. The reciprocating motion of a piston
is transformed into rotational motion
he reciprocating motion of a piston of
of a crankshaft on bearings
bearings mounted
transformed into rotational motion mounted
in a fixedinframe.
a fixed fram,
Double-lever Lever-crank Double-crank
mechanism mechanism mechanism

2018
SUKECSiHnOe
2018
The position sequence for the
li n k s in a slider-crank
SUKESH O P/ APME/ME407- MR - 2 0 18
mechanism
 Cam is a body which rotates or oscillates and in doing so imparts a
reciprocating motion to a second body called follower, with which
it is in contact.
 The length of times spent for the rotation is depending on the
shape of the cam.
Part
Part that lowersthe
that lowers
the follower,
follower, its
its profile Part
Part that
that drives
drives the
the
determining
profile how
determining how follower
follower upwards,
upwards, itsits
quickly
quickly thethe cam cam profile
profile determining
determining
follower
followerwill
will fall.
fall. how
howquickly
quickly the
the cam
cam
follower
followerwill
willlifted.
lifted.
Part
Part that
that allows
allows the the
follower
followerto toremain
remain at at
the
the same
same lever
leverforfor aa
significant
significant period
period of of
time
timeand andwhere
where its its
ccircular
ircular wwith
ith a a radius
radius
SUKESH O P/
 The cam shape required to produce a particular motion of the
follower will depend on the shape of the cam and the type of fo
llower used.
Dsi SpUa
l KcEeSHmOenPt/dAiPaMgEraM/ mE4f0o7r-
aMnR-e2c0c18entric cam
 Figure below shows the types of follower displacement diagrams
that can be produced with two other different shaped cams and
either point or knife followers.
(constant
(constantrate,
rate,
Heart
Heart uniform
uniform speed)
shap
shap speed)
ee
(rise
(riseand
andfall
fall
Pear
Pear
symmetrical
symmetrica
shap
shap
ly)
lly)
ee
2018
 Figure below shows a number of examples of different types of
cam followers.
Point Knife Roller
Lower
Lower friction
frictionthan
than
sliding
sliding contact
contact but
but
can
can be be more more
expensive
expensive
2018
 Figure below shows a number of examples of different types of
cam followers.
Sliding and oscillating Flat Mushroom
Ofte
Often use
nused because
because d –
cheaper and –can
be made and
cheaper smallercan
be
h
t a
made
n
smaller
follower
SUKESH Othan
P / APME/ME407-
 Gear trains are mechanisms which are very widely used to
transfer and transform rotational motion. They are used when a
change in speed or torque of a rotating device is needed. For
example, the car gearbox enables the driver to match the speed
and torque requirements of the terrain with the engine power av
ailable.
(a) Parallel gear axes, (b) axes inclined to one another, (c)
axial teeth, (SdU)KhEeSlHicaOl
P / A P M EM
/ E
4 0 7 - M R 2
- 0 1 8
 Two meshed gears.
 Gear ratio,
ωωAA == number
numberof
ofteeth
teethon
onBB == ddBB
ωωBB number
numberof
ofteeth
teethon
onAA ddAA
Angular Diamete
velocity r

2018
G = ωA = ωA ωB
G = ωA = ωA ωB
x
ωC ωB
ωC ωB
ωC
2018 ωC
 Compound gears trains – two wheels are mounted on a common sh
aft.
 Ratio of the angular velocities,

G = ωA = ωA ωB ωC = ωA ωC
G = ωD
ωA
ωD = ωA ωB
ωB x ωC
ωB ωC x ωC
ωD = ωA
ωD ωBx
ωB ωC
ωD
ωD
 For the input and output shafts to be in line, we must also have for the
radii of the gears.
r AKESH+rA
S U O Pr/ BAPME=/MEr40D7- MR+-201r8C
+ rB = rD +
Revolution Time
vv== nL
nL// tt==
fL
fL
Dsi tSaUnKcEe m o v e d p ar a e
S H O P / A
P M E M
/
l El40to7-
 Pair of rolling cylinders with the motion of one cylinder being transferred to
the other by a belt.
 Belt drives use the friction that develops between the pull eys attached to
the shaft and the belt around the arc of contact in order to transmit a
torque.
 The transmitted torque is due to the differences in tension that occur in the
belt during operation. This difference results in a tight side and a slack side
for the belt.

2018
 If the tension on the tight side is T1, and a slack side is T2, then with pulley
A as a driver,
Torque
Torqueon
onAA==(T1
(T1–– T2)
T2)
rA
 Pulley B as a driver, rA
Torque
Torqueon on B = (T1 – T2)

rB
rB
Since the power transmitted is the produce of the torque and the angular
velocity, and since the angular velocity is v/rA for pulley A and v/rB for
pulley B, then for either pulley we have
Power
Power==(T1 (T1–
SUKESTH 2O )P/vAPME/ME407- MR-
– T2) v
2018
 As a method of transmitting power between two shafts, belt drives have
the advantage that the length of the belt can easily be adjusted to suit a
wide range of shaft to shaft distance and the system is automatically
protected against overload because slipping occurs if the loading exceeds
the maximum tension that can be sustained by frictional forces.
 If the distance between shafts is large, a belt drive is more suitable than
gears, but over small distances gears are to be preferred.
 Different size pulleys can be used to give a gearing effect. However, the gear
ratio is limited to about 3 because of the need to maintain an adequate arc
of contact between the belt and pulleys.

2018
 Figure below shows two types of reversing drives.
 With both forms of drive, both side of the belt comes into contact with the
wheels and so V-belts or timing belts cannot be used.
Cross belt
Open belt
SUKESH O P/ APME/ME407- MR-2018
2018
 V
 V – belts are used with grooved pulleys and are less efficient that flat belts
but a number of them can be used on a single wheel and so give multiple
drive.
 Timing.
 Require toothed wheels, having teeth which fit into the grooves on the
wheel.
 Unlike the other belts, timing belt does not stretch or slip and consequently
transmits power at a c onstant angular velocity ratio .
 The teeth make it poss ible for the belt to be run at s low or fast speeds.

2018
 Whenever there is relative motion of one surface in contact with another,
either by rotating or sliding, the resulting frictional forces generate heat
which wastes energy and results in wear.
 The function of bearing is to guide with minimum friction and maximum
accuracy the movement of one part relative to another.
 Give suitable support to rotating shaft.
 The term thrust bearing is used for bearings that are designed to withstand
forces along the axis of a shaft when the relative motion is primarily
rotation.

2018
2018
2018
a)
a) Deep-groove
Deep-groove
b)
b) Filling-slot
Filling-slot
c)
c) Angular
Angularcontact
contact
d)
d)double-row
double-row
e)
e)Self-aligning
Self-aligning
e)
e)Thrust,
Thrust,grooved
grooved
race
race

2018
a)
a) Straight
Straightroller
b) Taper roller
roller
c)
b) Needle roller
Taper roller
c) Needle roller

2018
Electrical
43
Actuators
An actuator receiving electrical energy for motion is
called an electrical actuator.
1.Switching devices
1. Mechanical switches
1. Solenoids
2. Relays
2. Solid state switches
1. Diodes
2. Tyristors
3.Transistors
2.Drive system
2. DC motors
3. AC motors
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Hydraulics and
44
Pneumatics

2018
Hydraulic
45
s
 An actuator wherein hydraulic energy is used to impart motion is
called an hydraulic actuator.
 Hydraulic systems are power-transmitting assemblies employing
pressurized liquid as a fluid
for transmitting energy from an energy-generating source to an
energy-using point
to accomplish useful work.

2018
HYDRAULIC
46

SYSTEM
The basic rule of using hydraulic power is Pascal's Principle.
 Pascal's Principle: pressure exerted on a fluid is distributed
equally throughout the fluid.
Hydraulics uses incompresible liquids so the applied pressure from one end
(small arrow) is equal to the desired pressure on the other end (big arrow).
Hydraulic
47
s
1. Hydraulic pump unit : in an actual hydraulic system a pump converts
mechanical power into fluid power.
2. Control valve : the flow of pressurized liquid discharge by the pump is
controlled by valves.
 Pressure control valves- control the liquid pressure .
 Flow control valves : control the liquid flow rate.
 Directional control valve : control the direction of
flow of the liquid.

2018
Hydraulic
48
s
3. hydraulic motor/cylinder
 The liquid discharged by the pump is directed to hydraulic motors or
cylinders by control valves.
 Motors are used where rotory motion is desired and cylinders are
used where linear motion is necessary.

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HYDRAULIC
49
ACTUATOR
Hydraulic systems are used to control & transmit power.

•A pump driven by prime mover (electric motor) creates flow of fluid

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Hydraulic
50
system
SUKESH OOP/P/APME/ME407-
SUKESH APME/ME407-MR-
MR-2018
10/16/18
2018
51

SUKESH
2018 O P/ APME/ME407- MR-2018
Functions of the
52
components
1. The hydraulic actuator is a device used to
convert the fluid power into mechanical
power to do useful work. The actuator may be
of the linear type (e.g., hydraulic cylinder) or
rotary type(e.g., hydraulic motor) to provide
linear or rotary motion, respectively.

2018
Functions of the
53
components
2. The hydraulic pump is used to force the fluid from the reservoir to
rest of the
hydraulic circuit by converting mechanical energy into hydraulic
energy.
3. Valves are used to control the direction, pressure and flow rate of a
fluid flowing
through the circuit.
4. External power supply (motor) is required to drive the pump.
5. Reservoir is used to hold the hydraulic liquid, usually hydraulic oil.

2018
Functions of the
54
components
6. Piping system carries the hydraulic oil from one place to another.
7. Filters are used to remove any foreign particles so as keep the fluid
system clean
and efficient, as well as avoid damage to the actuator and valves.
8. Pressure regulator regulates (i.e., maintains) the required level of
pressure in
the hydraulic fluid.

2018
Hydraulic actuators
- Economic
- Reliable
- Able to support heavy loads
- Resistant to overloads
- Low working speed
- Hydraulic group noisy in operation
- Possible oil leakage

2018
Pneumatic
56
s
Uses pressurised air to transmit and control power.
Air is used as the fluid because:-
 It is safe.
 It is less expensive and readily available
 It can be inducted and exhausted directly to the atmosphere and
return line is not necessary as with hydraulics.

2018
Pneumatics
57
System

2018
Functions of the
58
components

2018
Functions of the
59
components
Pneumatic systems are systems always

processing new air (where as hydraulic
systems are closed systems always
returning the oil)

2018
Pneumatic actuators (cylinders)
- Economic
- Reliable
- High operation speed
- Operation at constant force
- Resistant to overloads
- No speed control
- Poor position speed
- Noisy operation
2018
Comparison between Hydraulic and Pneumatic
system
61 S. Hydraulic System Pneumatic System
No.
1. It employs a pressurized liquid as a It employs a compressed gas,

fluid usually air, as a fluid
2. An oil hydraulic system operates at A pneumatic system
pressures up to 700 bar usually operates at 5–10 bar
3. Generally designed as closed system Usually designed as open system
4. The system slows down when leakage Leakage does not affect the system
occurs much
5. Valve operations are difficult Valve operations are easy
6. Heavier in weight Lighter in weight
7. Pumps are used to provide Compressors are used to provide
pressurized liquids compressed gases
8. The system is unsafe to The is free from fire
fire hazards system
9. Automatic lubrication is provided hazards arrangements for
Special
ul b r ci a oitn are
SUKESH O P/ APME/ME407- M R -2 0 1 8
HYDRAULIC
62
ACTUATOR

2018
Linear Actuators -
CYLINDERS
63

2018
Parts of linear
64


actuator
Cylinder barrel
Cylinder base or cap
Piston
Piston rod
 Cylinder head Rod gland
 Other parts : Cylinder base connection - Seals-Cushions
MR-2018
10/16/18
2018
65

2018
66

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Single acting
cylinder
67
 In the case of a single acting cylinder, only the piston side is

pressurized with hydraulic fluid. The cylinder can thus carry out work
only in one direction.
 The fluid which flows into the piston chamber causes a pressure to
build up the surface of the piston.
 The piston travels into its forward end position. The return stroke is
effected by a spring, the dead eight of the piston rod or an external
load.

2018
68
MR-2018
10/16/18
2018
PLUNGER TYPE
69
ACTING
SINGLE
CYLINDER
In the case of plunger cylinders, the piston and rod form a single
component.
 Due to the design of the cylinder, the return stroke can only be
effected by external forces.
 The cylinders can therefore generally be installed only
vertically.

2018
7
0

2018
71

2018
72

2018
73

2018
74

2018
DOUBLE ACTING
WITH
CYLINDER
75
END POSITION
CUSHIONING
Cylinder with end position cushioning are used to brake high stroke
speeds smoothly and prevent hard impacts at the end of the stroke.
Shortly before the end position is reached, the cross- section for the
outflow of fluid is reduced by the built-in cushioning pistons and then
finally closed. The hydraulic fluid is then forced to escape through a
flow control valve.

2018
76

2018
7
7

2018
Cylinder
78
cushioning

2018
7
9

2018
80

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Through rod
81
cylinder

2018
tandem
82
cylinder

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ROTARYACTUATORS
83

ASSIGNMENT QUESTION
HYDRAULICS & PNEUMATICS: :
 Gear motor
 Vane motor
 Piston motor
 Turbine motors
 Gerotor type
motors

2018
Module-
84
II
 Directional controlvalves, pressure
control valves, process control valves.

2018
Control
85
valves
 Fluid power is controlled primarily through the
use of control devices called valves.
 Hydraulic and pneumatic systems require
control valves to direct and regulate the flow of
fluid and regulate the flow of fluid from pump(or
compressor) to hydraulic cylinders or motors.
1. Direction control valves
2. Pressure control valves
3. Process control valves (flow)

2018
Flow control
valves
 These valves are used to control the speed
of hydraulic actuator by controlling the flow
rate or discharge
1. Needle valve
2. Gate and globe valve

2018
1. Needle valve
 It is the most common hydraulic flow
control device.
 It consists of a needle or pointed threaded
stem that can be adjusted manually to
control the flow or discharge through the
valve. It is made of steel.
 This valve can also be used as a stop valve
to prevent the flow of fluid from one part of
the hydraulic circuit to another.

2018
Needle valves

2018
Globe valve
 In this valve the flow area is larger than that of a
needle valve. Hence globe valve will have a larger
flow capacity at a lower pressure drop than a
needle valve of the same size.
 Globe valves have a round disk to control or stop
the fluid flow.
 Needle valves are suitable for throttling i.e., the
flow area is slowly reduced as the valve is closed,
gradually reducing the quantity of fluid passing
through the valve. But the globe valves are not so
suitable for thSrUoKEtStHliOnPg/ AfPMuEn/McEt4i0o7-nMR. -2018
SUKESH O APME/ME407- MR-2018
P/
Gate valve
 Gate valves are not normally used as flow control
valves. Most of the gate valves are used as stops
to shutoff fluid flow (or) to open the line to full
flow.
 Gate valves provides a opening with minimum
pressure drop.

2018
2018
Pressure control valves
 These valves control the pressure of flow medium
required by the system..
 To regulate or reduce oil pressure in certain portions of
the circuit
 to unload system pressure.
 To limit maximum system pressure as a safety
measure.
 To assist sequential operation of actuators in a circuit
by pressure control.
 To perform any other pressure related functions by
virtue of presSsUuKrEeSHcOoPn/tArPoMEl./ME407- MR-2018
Type
s
1. Pressure relief valve.
2. Pressure sequencing valve.
3. Pressure reducing or regulating valve.
4. Pressure unloading valve.
5. Pressure brake valve.

2018
1. Pressure relief valves
 These valves are found in every hydraulic system.
 It is normally closed valve, connected
between the pressure line and the oil
reservoir.
 Its main purpose is to limit the presure in a system
to a prescribed maximum by diverting some or all
of the pump output to the tanks, when the desired
set pressure is reached.

2018
PRV

2018
2. Pressure sequencing valve
 Sequence valve is used to direct the flow to more
than one portion of a fluid circuit in sequence.

2018
2018
3.Pressure reducing valve
 This type of valves are normally open
pressure control valves used to maintain
reduced pressures in certain portions of the
hydraulic system.
 These are actuated by the pressure sensed
in the branch circuit and tend to close as it
reaches the pressure of the valve setting
preventing further buildup of pressure.

2018
2018
4. Pressure unloading valve
 This type of valves is used to unload the
energy in a system of a lower pressure.
 This valve allows pressure to build up to an
adjustable setting and then bypasses the flow
as long as a remote source maintains the
preset pressure on the pilot port.
 Unloading valves are normally used in double
pump applications. When the high speed and
more flow are not required.
SUKESHOP/APME/ME407- MR-2018
Direction control valves
 The direction control valvea start, stop and control the
direction of flow for reversing the direction of motion of
the actuator.
Dcv
8
1. Check valve
 Check valve is a one way valve because it permits
flow in only one direction and prevents any flow in
the opposite direction.
Pilot operated check valve
 The pilot operated check valve always permits free
flow in one direction but permits flow in the
normally blocked opposite direction only if pilot
pressure pushes the pilot piston sownward.

2. Poppet valve
 It is a check valve that can be forced open to allow
reverse flow.
3. Spool valve
 It consists of a cylindrical spool with multiple lobes
moving within a cylindrical casing containing
multiple ports.
 The spool can be moved back and fourth to align
spaces between the spool lobes with input and
output ports in the housing to direct high pressure
flow to different circuits in the system.
Spool valve
4. Shuttle
valve
 This is the another type of direction control valve.
 It allows a system to operate from either of two
fluid power sources.
 It is also known as a double check valve. It
is mostly used in pneumatic device and is
rarely used in hydraulic circuits.
Shuttle valve
114
Two way valv e
SUKES OO PP// AAPPMMEE//MMEE407-

H 407- MMRR--20182018
(Normally opened)
(Normally Closed)
SUKESHOP/APME/ME407- MR-
2018
Two-way two-position
directional control valve
 Gate valve is example of 2W/2P directional control
valve which either turns on or off the flow in
normal or working positions depending on need of
application.
 Here arrow indicates that fluid flow is taking place
whereas other position shows cut-off position.
Three way valve
117

2018
Three-Way Direction
Control 3/2-Way DCV
(Normally opened)
(Normally Closed)
Four way valves
Four way
valves
Four-way two-position
directional control valve
 4/2 valve has four connections to it and two valve
positions. Normally, one port is open to flow from
the pump.
Four-way three-position
directional control
valve
It has one way for pump (P), one for reservoir (R)
or tank (T) and two for the inlet to the actuator.
And it has 3 positions: one normal, one cross way,
and one straight way.
SINGLE ACTING HYDRAULIC
CYLINDER CIRCUIT
 2POSITION , 2WAY DCV
Double ACTING HYDRAULIC
CYLINDER CIRCUIT
 Three position, four way
DCV
r
o SUKESHOP/APME/ME407- MR-2018

ME407 Mechatronic S: Sukesh O P Assistant Professor Dept. of Mechanical Engineering Jecc

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ME407 Mechatronic S: Sukesh O P Assistant Professor Dept. of Mechanical Engineering Jecc

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SUKESH O P/ APME/ME407- MR- 1

10/16/1 SUKESH O P/ APME/ME407- MR-

SUKESH O P/ APME/ME407- MR- 10/16/18

SUKESH O P/ APME/ME407- MR- 10/16/18

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SUKESH O P/ APME/ME407- MR- 10/16/18

SUKESH O P/ APME/ME407- MR- 10/16/18

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SUKESH O P/ APME/ME407- MR- 10/16/18

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 Linear actuator: solenoid, Hydraulic/Pneumatic.

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Translation motion Rotational motion

Movement which can be Rotation

(a) with two SUb( K)EwSHhtiOht Pr/eAePnModEeM

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 Ratio of the angular velocities,

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SUKESH O P/ APME/ME407- MR- 10/16/18

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Hydraulic systems are used to control & transmit power.

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Pneumatic systems are systems always

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1. It employs a pressurized liquid as a It employs a compressed gas,

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 In the case of a single acting cylinder, only the piston side is

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