By

V. THULASIKANTHAssistant Professor

Mechanical Engineering Departmentvtkvsk@gmail.com

ELEMENTS OF MECHATRONICS

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INTRODUCTION

Topics

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SL.NO TOPIC

1 Introduction to Mechatronics systems, Concepts & Application.

2 Mechatronics System Components with examples

3 Measurement Systems, Control systems, Open & Closed Loop Systems.

4 Sequential Controllers with examples – Water level controller.

5 Shaft speed control, Washing machine control.

6 Automatic camera and Engine management systems.

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The word mechatronics was originated from Japan (Yasakawa Electric Company) in the late 1960s, spread through Europe, and is now commonly used round the globe.

“The word, mechatronics, is composed of ‘mecha’ from mechanism and the ‘tronics’ from electronics.

Mechatronics solves technological problems using interdisciplinary knowledge consisting of mechanical engineering, electronics, and computer technology.

In 1996, Harashima, Tomizuka, and Fukuda defined mechatronics as being “the synergistic integration of mechanical engineering, with electronics and intelligent computer control in the design and manufacturing of industrial products and processes.”

Bolton presented yet another definition by saying “a mechatronic system is not just a marriage of electrical and mechanical systems and is more than just a control system; the mechatronic system is a complete integration of them all.”

Mechatronics is the field of study concerned with the design, selection, analysis, and control of systems that combine mechanical elements with electronic components, including computers and/or microcontrollers.

Introduction to Mechatronics Systems

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Mechatronics is the synergistic integration of sensors, actuators, signal conditioning, power electronics, decision and control algorithms, and computer hardware and software to manage complexity, uncertainty, and communication in engineered systems.

Working definition

Graphical Representation of Mechatronics

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Evolution of MechatronicsTechnological advances in design, manufacturing, and operation of engineered products/devices/processes can be traced through:

– Industrial revolution– Semiconductor revolution– Information revolution

Industrial Revolution

• Allowed design of products and processes for energy conversion and transmission thus allowing the use of energy to do useful work.

• Engineering designs of this era were largely mechanical – e.g., operations of motion transmission, sensing, actuation, and computation were performed using mechanical components such as cams, gears, levers, and linkages).

• Purely mechanical systems suffer from– Power amplification inability.– Energy losses due to tolerances, inertia, and friction.

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Semiconductor Revolution

• Led to the creation of integrated circuit (IC) technology.

• Effective, miniaturized, power electronics could amplify and deliver needed amount of power to actuators.

• Signal conditioning electronics could filter and encode sensory data in analog/digital format.

• Hard-wired, on-board, discrete analog/digital ICs provided rudimentary computational and decision-making circuits for control of mechanical devices.

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Information Revolution• Development of VLSI technology led to the introduction of microprocessor, microcomputer, and microcontroller.

• Now computing hardware is everywhere, cheap, and small.

• As computing hardware can be effortlessly interfaced with real world electromechanical systems, it is now routinely embedded in engineered products/processes for decision-making.– Microcontrollers are replacing precision mechanical components, e.g., precision machined camshaft that in many applications functions as a timing device.

– Programmability of microcontrollers is providing a versatile and flexible alternative to the hard-wired analog/digital computational hardware.

– Integrated computer-electrical-mechanical devices are now capable of converting, transmitting, and processing both the physical energy and the virtual energy (information).

• Result: Highly efficient products and processes are now being developed byjudicious selection and integration of sensors, actuators, signal conditioning, powerelectronics, decision and control algorithms, and computer hardware and software.

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Mechatronics has evolved through the following stages:

• Primary Level Mechatronics: Integrates electrical signaling with mechanical action at thebasic control level for e.g.fluid valves and relay switches

• Secondary Level Mechatronics: Integrates microelectronics into electrically controlled devices for e.g. cassette tape player.

• Tertiary Level Mechantronics: Incorporates advanced control strategy using microelectronics, microprocessors and other application specific integrated circuits for e.g. microprocessor based electrical motor used for actuation purpose in robots.

• Quaternary Level Mechatronics: This level attempts to improve smartness a step ahead by introducing intelligence ( artificial neutral network and fuzzy logic ) and fault detection and isolation ( F.D.I.) capability into the system.

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Mechatronics Applications• Smart consumer products: home security, camera, microwave oven, toaster, dish washer, laundry washer-dryer, climate control units, Automatic Digital Cemera etc.

•Computer disk VCR/DVD drives, ATM, etc

• Medical: implant-devices, assisted surgery, haptic, etc.

• Defense: unmanned air, ground, and underwater vehicles, smart weapons, jet engines, etc.

• Manufacturing: NC & CNC machine tools, Rapid Prototyping, robotics, etc.

• Automotive: climate control, antilock brake, active suspension, cruise control, air bags, engine management, safety, etc.

• Network-centric, distributed systems: distributed robotics, telerobotics, intelligent highways, etc.

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Advantages of Mechatronics

Cost effective and good quality products

High degree of flexibility to modify or redesign

Very good performance characteristics

Wide are of application

Greater productivity in case of manufacturing organization

Greater extend of machine utilization

Disadvantages of MechatronicsHigh Initial cost

Multi-disciplinary engineering background required to design and implementation

Need of highly trained workers

Complexity in identification an correction of problems in the system

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Elements of Mechatronics System Actuators & Sensors

Signals & Conditioning

Digital Logic System

Software & Data acquisition Systems

Computers & Display devices

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Actuators & SensorsSensors and actuators come under mechanical systems

Actuators Sensors

The actuators produce motion or cause some action

The sensors detect the state of the system parameters, inputs and outputs

Various actuators: Pneumatic an hydraulic actuators, Electro Mechanical actuators, Piezoelectric, Electrical Motors, i.e. D.C, A.C, Stepper, Servo motors.

Various Sensors: Liner and rotaional sensors, acceleration sensors, force, torque, pressure sensor, temperature, proximity and light sensors.

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Signals & ConditioningMechatronic system deals with two types of signals and conditioning , i.e.

Input & Output

Input devices receive input signals from the mechatronics system via

interfacing devices an sensors.

From sensors the signal is send to the control circuits for conditioning or

processing.

Various input signal conditioning devices are amplifiers, A2D, D2D converters .

Output signals from the system are send to the output/display devices through

interfacing devices

Various output signal conditioning devices are D2A, display decoders, power

transistors, op-amps.

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Digital Thermometer

The thermocouple is a transducer that converts temperature to a small voltage; the amplifier increases the magnitude of the voltage; the A/D (analog-to-digital) converter is a device that changes the analog signal to a coded digital signal; and the LEDs (light emitting diodes) display the value of the temperature.

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Digital Logic SystemIt will control overall system operation

Various digital logic systems are logic circuits, microcontrollers, PLC, sequencing & timing controls

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Software & Data acquisition SystemsData acquisition system acquires the output signals from sensors in the form of voltage, frequency, resistance etc. an inputting into the microprocessor or computer.

Software is used to control the acquisition of data through DAC board.

Data acquisition system consists of multiplexer, amplifier, register and control circuits.

Software Examples: Ladder Logic, Visual C++, Visual Basic, Lab VIEW, MATLAB, Lab Chart, LOX

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Using Lab VIEW

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Computers and display devices Computers are use to store large amount of data and process further through software.

Display devices are used to give visual feedback to the user.

Display devices are LED, CRT, LCD, Digital displays etc.

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Measurement System

What is a system?

MOTOR

Input, Electrical Power

Output, Rotaion

Not concentrate on what goes on inside

Concentrate only on output & Input device

Measurement system?

Measuring Input quantityOutput the value of quantity

Measurement System

ThermometerInput Temp.Output number on scale

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Digital Thermometer

The thermocouple is a transducer that converts temperature to a small voltage; the amplifier increases the magnitude of the voltage; the A/D (analog-to-digital) converter is a device that changes the analog signal to a coded digital signal; and the LEDs (light emitting diodes) display the value of the temperature.

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Control SystemTo control the output to some particular value or particular sequence of values

Central Heating system

Input, required temperature

Output, temperature at the set value

Difference between Open loop and Closed loop system

SI.No. Open loop system Closed loop system

1 Not using feedback Feedback using

2 Less accurate More accurate

3 Simple in construction Complicated in construction

4 Optimisation in control is not possible Optimisation in control is possible

5 Easy maintenance & cost is less Difficult to maintain & cost is more

6 Eg. CD deck, Digital thermometer Eg. Automatic water level, washing machine

Open Loop system

Closed loop system

Basic Elements of a closed loop system

1.Comparison element2.Control element3.Correction element4.Process elements5.Measurement elements

Various elements for controlling the room temperature.

Controlled variable - the room temperatureReference value - the required room temperatureComparison element - the person comparing the measured value wit required temp.Error signal - difference between measured and required temperaturesControl unit - the personCorrection unit - the switch on the fireProcess unit - the heating by the fireMeasuring device - a thermometer

Shaft Speed Control

Water Level Controller

Washing machine control

Cam operated Switch

Engine Management system

Automatic Camera

The Digital Camera