Mechatronics

 Mechatronics is an engineering discipline, which integrates Electrical, Electronics,

Computer science and Control engineering with Mechanical Engineering for design and
manufacturing of engineering product/systems.
Mechatronics basically refers to mechanical electronics systems and normally described
as a synergistic combination of mechanical, electrical electronics, computer and control
engineering which when combined, make possible the generation of simple, more
economical and reliable systems.
Need for Mechatronics
 To adopt an interdisciplinary and integrated approach in engineering.
 Globalisation.
 Effective use of automation.
 Greater focus on quality management.

Advantages
 Compact sized products/systems.
 Accurate systems, Precise operations
 Lighter structures.
 Automatic, programmable systems.
 More features, Improved flexibility, Environment friendly.
 Effective use of automation.
 Greater focus on quality management.
Mechatronic System
A system may be defined as a group of elements or devices combined to achieve the
required or desired outputs for the given inputs.

Input Output
System
A mechatronic system consists of more than one system which helps in the functions of
the device. Physically a mechatronics system is composed of four prime components. They
are sensors, actuators, controllers and mechanical components.
Examples: A robot, A computer disk drive, washing Machine etc.
The two important systems employed in mechatronics are Measuring system and control
system.

Control System
A control system is a device used to control its output to some particular predetermined
value.
Example: In a domestic air conditioner, the input is the temperature required in the house
and output is house attaining the set temperature.

Required Input AC Output Temperature of the house

Temperature System maintained at set value.
Types of Control Systems
There are two Types of control systems:
1) Open Loop control System
2) Closed loop control System
1) Open Loop control System
A open loop control system, the input is controlled without any reference to the output.
Thus the output is independent of the control action at the input. In these systems the
output is neither measured nor compared with the input. In open loop systems, there is no
feedback from the output to the input.

Input Control Processing Output

Unit Unit
Example: Traffic Signal
Here the changeover of Red, Green, yellow lights will be presented by a timer mechanism
which is for a fixed interval of time. No action is taken for the varied traffics rate.
Example: Ceiling fan
Here the changeover of fan speed is based on the manual adjustment of the fan
regulator. The fan speed remains unaffected with change in room temperature. The fan
speed has no control over the temperature of the room.
Other Example: Electric bulb , Electric hand drier, Cranes, Hydraulic jack, Electric stove etc
 2) Closed Loop control System
A closed loop control system is one in which the output signal has a direct affect on the
control action . Thus, any system that automatically correct for variations in its output is a
closed loop control system. Feed back occurs from the output to input.
Comparing
Element
Reference Error Control Correction Controlled
Input Signal Unit Unit Process
Variable
(Output)

(F eed Back) Measuring

Measured Value Device
Error = Reference value- Measured Value
Pivot
Example: Water Level Indicator
Controlled Variable: water level in the tank Lever
Reference Variable: Initial lever arm setting Float
Comparison element: Actual lever position
Error: Difference in actual and initial position
Control unit: The pivoted lever arm
Correction unit: opening and closing of the flap for water
Process: water level control
Measuring Device: F loat and lever
Water
Other Example: Electric iron, Electric Geyser, Operation of lift doors, Air conditioners etc Input
 Example

Domestic Air Conditioner as an example for Closed Loop Control System

Comparing
Set Room
Temperature Element ON Air Cold air
(20 °C) (- 1°C) Signal Switch/relay conditioner to room
Reference Error Control Correction ON Controlled
Input Signal Unit Unit Process
OFF Variable
OFF
(+ 2 °C) (Output)
Signal
(18 °C) (F eed Back) Measuring Temperature of
(21 °C) Measured Value Device the Room

Case 1: if Measured Value = 18 °C Case 2: if Measured Value = 21 °C

Error = Reference value- Measured Value Error = Reference value- Measured Value
= 20 °C - 18 °C = 20 °C - 21 °C
Error = +2 °C Error = - 1 °C
Difference between Open loop and Closed Loop Control System
 Advantages and Disadvantages of Open Loop Control System
Advantages:
1) Simple and Economical
2) Less maintenance
3) Reliable
Disadvantages:
1) Inaccurate since there is no correction
2) System cannot adopt for varying condition
3) Relatively slow in response

Advantages and Disadvantages of Closed Loop Control System

Advantages:
1) Since there is a feed back, any error can be eliminated
2) Output is controlled as required
3) Increased accuracy
4) Increase the the performance efficiency of the system
Disadvantages:
1) Complexity
2) Increased cost
3) High maintenance
 Introduction to Robotics
Robotics
It is an interdisciplinary application of mechatronics (Mechanical, electrical, electronics,
computer engineering etc) which involves design, construction, operation and use of
robots. The goal of robotics is to design machines that can help and assit humans
replicating human actions. Robots are widely used for automatic material handling and
automation in mass production.

Application
Robot today are used in dangerous environments (Including inspection of radioactive
materials, bomb detection and deactivation, manufacturing process, or where humans
cannot survive (e.g. in space, underwater, in high heat, and clean up and containment of
hazardous materials and radiation). Certain advanced robots attempt to replicate walking,
lifting, speech, cognation, or any other human activity. Many of today’s robots are
inspired by nature, contributing to the field of bio-inspired robotics.

Note
Bio-inspired robotics is about studying biological systems, and
look for the mechanisms that may solve a problem in the
engineering field. The designer should then try to simplify and
enhance that mechanism for the specific task of interest.
Advantages and Disadvantages
 Basic Joints and Links in Robotics

The members of a robotic manipulator are called as Links. These links connected
together by Joints.
Types of joints based on relative motion between the links: : Types of joints based on
relative motion between the links:

1. Prismatic(linear) joints
2. Rotational joints
3. Twist joints
4. Revolute joints
1. Prismatic(linear) joints
Joints formed by two links having linear relative motion between them are called as
Prismatic joints. Such two links can slide with respect with each other. Linear (L) , and
Orthogonal(O). types of prismatic joints are possible

Fig. Linear Joint Fig. Orthogonal Joint Fig. Symbolic Representation

 Basic Joints and Links in Robotics

2. Rotational joints
Joints formed by two links having rotary relative motion between them are called as
Rotational joints(R).

Fig. Rotational joints Fig. Symbolic Representation

3. Twist joints

Fig. Twist joints

Fig. Symbolic Representation
4. Revolute joints

OR
Robotics Configuration
Robotics Configuration
Automation
 Automation is the use of machines, control systems, and information technologies to
optimize productivity in the manufacturing processes with little human involvement.
 Industrial automation helps us to process the plant operation in more optimized
conditions by using various control systems such as Programmable Logic Circuit
(PLC), Human-machine Interface (HMIs), and robotics
 It is technology concerned with the application of Mechanical, electronic &
computer-based systems to operate and control production activates in order to
improve the quality and quantity of production
 Automation Includes the following:
 Automated machine tools.
 Automated assembly machines
 Industrial robots.
 Automated material handling & storages system.
 Automated inspection system for quality control.
 Feedback control & computer process control.
 Computer integrated system for planning, data collection and decision making.
Types of Automation
Automated production systems are classified into three basic types:
1) Fixed (Hard) Automation
2) Programmable Automation
3) Flexible (soft) Automation
4) Totally Integrated Automation (TIA)
F ixed (Hard) Automation
 Fixed automation is a system in which the sequence of processing (or assembly)
operations is fixed by the equipment configuration.
 The operations in the sequence are usually simple.
 It is the integration and coordination of many such operations into one piece of
equipment that makes the system complex.
 The typical features of fixed automation are:
• High initial investment for custom-engineered equipment.
• High production rates.
• Relatively inflexible in accommodating product changes.

Advantages
 High production rates
 Low unit cost
Disadvantages
 The initial investment is high
 High chance for failure
Programmable Automation
 In programmable automation, the production equipment is designed with the
capability to change the sequence of operations to accommodate different product
configurations.
 The operation sequence is controlled by a program, which is a set of instructions
coded so that the system can read and interpret them.
 New programs can be prepared and entered into the equipment to produce new
products.
 The typical features of programmable automation are:
• High investment in general-purpose equipment
• Low production rates relative to fixed automation
• Flexibility to deal with changes in product configuration
• Most suitable for batch production.

Advantages Disadvantages
 Very flexible.  High investment.
 Able to deal with design variations. Production rate is low than fixed automation
 Appropriate for batch production.
F lexible Automation
 The concept of flexible automation has developed only over the last 15 to 20 years,
and the principles are still evolving.
 A flexible automated system is one that is capable of producing a variety of products
(or parts) with virtually no time lost for changeovers from one product to the next.
 There is no production time lost while reprogramming the system and altering the
physical setup (tooling, fixtures and machine settings).
 Consequently, the system can produce various combinations and schedules of
products, instead of requiring that they be made in separate batches.
 The features of flexible automation can be summarized as follows:
• High investment for a custom-engineered system.
• Continuous production of variable mixtures of products.
• Medium production rates.
• Flexibility to deal with product design variations.
Advantages
 Continuous production of variable mixtures of products.
 Flexible to deal with product design variation.
 The production rate is medium.
Disadvantages
 High investment
 Cost is high compared to fixed automation.
Totally Integrated Automation (TIA)
Integrated industrial automation refers to the comprehensive automation of production
operations, in which all processes are coordinated digitally and controlled by computers.
It includes technology such as:
 Computer-aided process design
 Machine systems that are adaptable
 Machine tools for computer numerical control
 Material-handling robots are examples of automated material-handling systems.
 Systems for automatic storage and retrieval
 Control of production and scheduling by computer
 Conveyors and cranes that are automated.
 Advantages and Disadvantages of Industrial Automation

Advantages
 The task performed by human operators involving tedious physical work can be easily
replaced.
 Increase production.
 Reducing cost, especially, human-related cost.
 Improving the quality of the product.
 Efficient use of raw materials.
 Reduce energy consumption.
 Increase business profits.

Disadvantages
 Loss of jobs. Since, majority of the work is done by machines, the requirement for manual
labor is very less.
 All the desired tasks cannot be automated using the current technology. For example,
products with irregular shapes and sizes are best left for manual assembly. (This trend
seems to be changing with advanced computers and algorithms).
 It is feasible to use automation for certain process i.e. high-volume production, repeatable
and consistent products.
 The initial cost of implementing an automation system is very high.
 A set of skilled personnel is always a requirement for maintenance and service.