Mechatronics

Course Code:
ME401
Instructor: Dr.
Abhinav Kumar
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 Emergence of
Mechatronics
Advancements in semiconductor and integrated circuits
manufacturing led to the development of a new class of products that
incorporated mechanical and electronics in the system.

MECHAnics and elecTRONICS -> MECHATRONICS

- Yaskawa Electric Company, Japan (1960s)

Initially, mechatronics referred to systems with only mechanical

systems and electrical components—no computation was
involved. Examples of such systems include the automatic sliding
door, vending machines, and garage door openers.

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 Definitio
Mechatronics is a
n
synergistic
integration of electronic engineering,
electrical engineering, computer
technology and control engineering with
mechanical engineering.
Harashima,
Tomizuka,
and Fukada
(1996)

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 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.

– Network-centric, distributed systems: distributed robotics,

tele-robotics, intelligent highways, etc.
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 Control System

A control system can be thought of as a system which can be used to:

• control some variable to some particular value, e.g. a central heating
system where the temperature is controlled to a particular value;
• control the sequence of events, e.g. a washing machine where when
the dials are set to, say, ‘white’ and the machine is then controlled to
a particular washing cycle, i.e. sequence of events, appropriate to
that type of clothing;
• control whether an event occurs or not, e.g. a safety lock on a
machine where it cannot be operated until a guard is in position.

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 Control System- Open Systems

A control system cam be said as open when there is no feedback available

to it.

• An example of an everyday open-loop control system is the domestic

toaster. Control is exercised by setting a timer which determines the
length of time for which the bread is toasted. The brownness of the
resulting toast is determined solely by this preset time. There is no
feedback to control the degree of browning to a required brownness.

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 Control System- Closed-loop
Systems
• A control system can be said as closed loop when it has feedback system

• The term feedback is used because signals are fed back from the output
in
order to modify the input.

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 Elements of Closed-loop
Systems
• Comparison element:- error signal= reference value signal - measured
value signal
• Control element:- It decides what action to take when it receives an error
signal.
• Correction element:- The correction element produces a change in the
process to correct or change the controlled condition. Ex- Actuator,
Relay
• Process element:- The process is what is being controlled.
• Measurement element:- It produces a signal related to the variable
condition
of the process that is being controlled.

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Elements of Closed-loop
Systems

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Control System- Closed-loop
Systems

Figure. The automatic control of water level

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Control System- Closed-loop
Systems

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 Sequential Controllers

• The term sequential control is used when control is such that

actions are strictly ordered in a time- or event-driven
sequence.
• Such control could be obtained by an electric circuit with sets of
relays or cam-operated switches which are wired up in such
a way as to give the required sequence.
• Such hard-wired circuits are now more likely to have been
replaced by a microprocessor-controlled system, with
the sequencing being controlled by means of a software
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Sequential Controllers

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14
 Programmable logic controller
• (PLC)
It is a microprocessor-based controller which uses
programmable memory to store instructions.
• It implement functions such as logic, sequence, timing,
counting and arithmetic to control events and can be
readily reprogrammed for different tasks.
• For example, they might be used in

process control where a tank of

liquid is to be filled and then heated

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 Programmable logic controller
•
(PLC)
The control sequence might thus be as follows:-
• switch on pump to move liquid into the tank.
• switch off pump when a level detector gives the on signal, so indicating
that the liquid has reached the required level.
• switch on heater.
• switch off heater when a temperature sensor gives the on signal to
indicate the required temperature has been reached.
• switch on pump to empty the liquid from the container.
• switch off pump when a level detector gives an on signal to indicate
that the tank is empty.
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 MEMS and the Automobile
Airbag
• Microelectromechanical systems (MEMS) are mechanical
devices that are built onto semiconductor chips,
generally ranging in size from about 20 µm to few mm
and made up of components 0.001 to 0.1 mm in size.
• Airbags in automobiles are designed to inflate in the event of a
crash and so cushion the impact effects on the
vehicle occupant. The airbag sensor is a MEMS
accelerometer with an integrated micromechanical element
which moves in response to rapid deceleration.
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 Questions for Assignments:

• Explain the difference between open- and closed-loop

control and its components with examples.
• Explain the function of a programmable logic controller.
• Explain the elements of mechatronic systems.
• Explains the needs & benefits of mechatronics
in
manufacturing.

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 Sensors

• It is defined as an element which produces signal relating to

the quantity being measured.
• According to the Instrument Society of America, sensor can be
defined as “ A device which provides a usable output
in response to a specified measurand.
• Output is usually an ‘electrical quantity' and measurand is a
‘physical quantity’ i.e. Temperature, pressure, etc.

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 Transducers

• It is defined as a device that converts a signal from one form of

energy to another form.
• Piezoelectric transducers (convert mechanical vibrations
into electrical signals), etc.
• Sensors are a subset of transducers. All sensors
are
transducers, but not all transducers are sensors.
• Sensors output is only electrical signals, whereas transducers
output can be electrical, mechanical, thermal.
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 Specification of
Sensors/Transducers
• Range:- Indicates the limits between which the input can vary.
• Span:- Difference between the maximum and minimum values
of the input.
• Error:- Difference between the result of the measurement and
the true value of the quantity being measured.
• Accuracy:- It is defined the closeness of the
agreement between the actual measurement result and a true
value of the
measurand.
• Ex:- An accuracy
expected of ±2°C
to lie within mean
plus or that2°C
minus theofreading
the truebyvalue.
the sensor
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 Specification of
Sensors/Transducers
• Sensitivity:- It is defined as the ratio of change in output value
of a sensor to the per unit change in input value.
• Nonlinearity:-It indicates the maximum deviation of the
actual measured curve of a sensor from the ideal curve.

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 Specification of
Sensors/Transducers
• Hysteresis:- An error of a sensor, which is defined as the
maximum difference in output at any measurement value
within the sensor's specified range when approaching the
point first with increasing and then with decreasing the input
parameter.

Response time:- It describes

the speed of change in the
output on a step-wise change of
the measurand. 23
 Specification of
Sensors/Transducers
• Resolution:- The smallest detectable incremental change
of
input parameter that can be detected in the output signal.
Ex:- A sensor measures a displacement up to 20 mm and it
provides an output as a number between 1 and 100, then the
resolution of the sensor device is 0.2 mm.
• Stability:- It is the ability of a sensor device to give same output
when used to measure a constant input over a period of
time.
• Dead band/time:- The dead band or dead space of a
output. 24
 Types of Sensors/Transducers
• Displacement, position and proximity sensors
• Potentiometer • Velocity and motion
• Strain-gauged element • Incremental encoder
•
• Tachogenerator
Capacitive element
• Pyroelectric sensors
• Differential transformers • Force
• Eddy current proximity sensors • Strain gauge load cell
• Fluid pressure
• Inductive proximity switch • Diaphragm pressure
• Optical encoders gauge
• Pneumatic sensors
• Capsules, bellows,
pressure tubes
• Proximity switches (magnetic) • Piezoelectric
• Hall effect sensors sensors 25
 Types of Sensors/Transducers
• Temperature
• Bimetallic strips
• Resistance temperature detectors
• Thermistors
• Thermo-diodes and transistors
• Thermocouples
• Light sensors
• Liquid flow
• Photo diodes • Orifice plate
• Photo resistors • Turbine meter
• Liquid level
• Photo transistor • Floats
• Differential pressure
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27
 Electrical Actuators
• Electrical actuators are devices that convert electrical
energy into mechanical motion or physical displacement.
• Electrical actuators are used control and
to
mechanical systems, providing precise manipulate and
movement.
• Ex:-Solenoids, relays, diodes, thyristors, triacs,controlled
BJT, FET, DC
motor, Servo motor, BLDC Motor, AC Motor, stepper motors.

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 Solenoids

• Solenoids are electromagnetic devices that generate linear

motion when an electrical current passes through a coil.
• It consist of a coil of electrical wire with an armature which is
attracted to the coil when a current passes through it
and produces a magnetic field.
• The movement of the
armature contracts a return
spring which then allows
the armature to return to
its original position when 29
 Relays
• These are electrically operated switches that open and
close the circuits by receiving electrical signals from outside
sources.
• With small input current, a device carrying larger current can be
switched on or off.

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 Relays

Fig. Relay-controlled system

• A1 and B1 concurrently, then C1, followed by A2 and

B2 concurrently and finally C2. 31
 Diod
es
• It is a semiconductor device that allows current to flow in one
direction only. It consists of a P-N junction, which is the
interface between a region of semiconductor material with
an excess of positive charge carriers (P-type) and a
region with an excess of negative charge carriers (N-type)

Forward Bias

Reverse Bias

Fig. (a) Diode characteristics (V-I), (b) half-wave rectification. 32

Diodes

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 Diodes
• Depletion region:- It is a region in which there are no free electrons or holes
present at the p-n junction.
• The slight negative and positive charges across the depletion region will
produce an electric field in between. This electric field creates the
potential, which acts as a barrier for the natural flow of electrons.

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 Diodes-Application
• The most basic function would be changing AC current to DC
current by removing some part of the signal.
• Diodes help in performing digital logic.
• They are used for isolating signals from a supply. For example,
one of the major uses of diodes is to remove negative
signals from AC current. This is known as signal
demodulation. This function is basically used in radios as a
filtering system in order to extract radio signals from a
carrier wave.

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36
 Thyristors
• The thyristor, or silicon-controlled rectifier (SCR), can be
regarded as a diode which has a gate controlling the
conditions under which the diode can be switched on.

Fig. (a) Symbolic representation of

Thyristor Fig. Thyristor characteristics (V-I)

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 Thyristors
• The thyristor is a four
layered semiconductor
device with three
terminal namely Anode, Cathode
and Gate to control high power.
Fig. J2 is reverse bias

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Thyristors

Fig. P-N Junction.

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 Application

• Thyristors are used in applications that require controlled

switching of high-power loads, such as motor control,
AC power regulation, lighting control, etc.

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 Tria
c
• A Triac, short for "triode for alternating current," is an electronic
component that functions as a bidirectional
semiconductor switch. It is widely used in power
control applications for alternating current (AC) circuits.
• These are designed to control the
flow of current in both
directions through the circuit,
making
suitable them
for AC control
tasks power like lights,
dimming
controlling heating elements, and
motor speed regulation. Fig. Triac characteristic 41
 Tria
c
• The triac is similar to the thyristor and is equivalent to a pair of
thyristors connected in reverse parallel on the same chip.
The triac can be turned on in either the forward or reverse
direction.
• Advantage of Triacs is their ability to control AC power without
needing complex and bulky mechanical switches or
relay systems. This makes them particularly useful in
applications where fine control of power levels is required.

Fig. Voltage control: (a) thyristor, (b) triac. 42

 BJT (Bipolar Junction
•
Transistor)
A Bipolar Junction Transistor (BJT) is a three-terminal
semiconductor device that serves as an electronic amplifier
or a switch.
• BJTs are widely used in various electronic circuits for
applications such as signal amplification, voltage regulation,
current switching, and signal modulation.
• They come in two main types: NPN (Negative-Positive-
Negative) and PNP (Positive-Negative-Positive), each
having different arrangements of semiconductor layers.

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 BJT (Bipolar Junction
• Transistor)
The basic structure of a BJT consists of three semiconductor
regions: the emitter, the base, and the collector. These
regions are usually made from different types of
semiconductor material, such as P-type and N-type
silicon. The BJT operates based on the movement and
control of charge carriers (electrons and holes)
between these regions.

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 BJT (Bipolar Junction
In Transistor)
an NPN transistor: In a PNP transistor, the polarities are
• The emitter made of N-type reversed:
is
material and is the source of • The emitter is made of P-type
electrons. material and is the source of holes.
• The base is made of P-type material • The base is made of N-type material
and controls the current and controls the current
flow between the emitter and flow between the emitter and
collector. collector.
• The collector is made of N-type • The collector is made of P-type
material and collects the majority material and collects the majority
of the current from the emitter. of the current from the
• A Small base current is amplified to a emitter.
high collector current.

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BJT (Bipolar Junction
Transistor)

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BJT (Bipolar Junction
Transistor)

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 Applications
• Switching: BJTs can act as electronic switches, toggling between an on
and off state based on a control signal.
• Voltage Regulation: It provides stable and regulated output voltages can
be achieved, which is crucial for powering various electronic devices.
• Current Sources and Sinks: It is useful in applications like biasing other
transistors, generating reference currents, and controlling LED
brightness.
• Audio Amplification: BJTs are widely used in audio amplifiers to enhance
the audio signal from sources like microphones, musical instruments,
and media players.
• Darlington Pair: Two BJTs can be connected in a configuration known as a
Darlington pair to achieve higher current gain. 48
49
 Field Effect Transistor (FET)
• It is a type of semiconductor device widely used in
electronic circuits to amplify and switch electrical signals.

Fig. Schematic representation of BJT Fig. Schematic representation of FET

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 Field Effect Transistor (FET)
• The working principle of FET is analogous of a water pipe and
vessel connection.
• The source of water can be considered as the source terminal
of FET, while the vessel that collects water can be
analogous to the drain terminal of FET.
• The gate terminal can be compared to the controlling tap that
regulates the flow of water.
• The first terminal is the source (S), through which current
enters the device, denoted by IS.
• The second terminal is the drain (D), through which current
leaves the device, denoted by ID.
• The third terminal is the gate (G), which modulates the channel
conductivity. By applying a voltage at the gate, ID can
be controlled.

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Field Effect Transistor (FET)

• JFET:- Junction field effect transistor.

• MOSFET:- Metal oxide semiconductor field effect transistor.

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•
MOSF
An initial input potential creates a depletion region which does
ETnot allow the movement of charge carrier from source to
drain.
• A high input potential at gate terminal, sufficient electric field is
created to break the depletion region and allow the movement
of charge carrier.
• MOSFET is said to in ON state while there is a movement of
charge carrier.
• As movement of charge carrier can be done either by electrons
or holes, it is termed as unipolar device and is less noisy.

Fig. MOSFET OFF state Fig. MOSFET ON state 53

MOSFET

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 Difference between FET and
BJT
Sl. BJT FET
No.
1. It has 3 terminals namely base, collector It has 3 terminals namely gate, source and
and emitter. drain.
2. Bipolar device i.e. both holes and Unipolar device i.e. either holes or
electrons help in charge carrier. electrons helps in charge carrier.
3. Current control device i.e IC = f(IB) Voltage control device i.e. ID = f(VGS)
4. Input Impedance is less i.e. Low V & High I Input Impedance is high i.e. Low I & High V
5. More Noisy Less Noisy
6. Power consumption is more. Power consumption is less.
7. Shorter life and less efficient. Longer life and high efficient.
8. Bigger in size. Smaller in size.
9. Low Cost. High Cost.

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 Field Effect Transistor (FET)-
• Application
FETs (field effects transistors) are used in constructing mixer
circuits to restrict low intermodulation distortions.
• FETs are employed in low-frequency amplifiers because of
their relatively small coupling capacitors.
• FET is a voltage-controlled electrical device; due to this, it is
utilised in operational amplifiers in the form of variable
voltage resistors.
• Due to their large input Impedance, FET is typically used as
input amplifiers in electrical devices, i.e.
oscilloscopes, voltmeters, and other measuring tools.
• FET is also used to construct radio frequency amplifiers for FM
appliances.
• FET is used for the mixer operation of TV and FM receivers.
• Because of their small size, FETs are also used in LSI (large-
scale integration) and computer memory modules..
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