MECHATRONICS

(Course Code:18ME36B)

Department of Mechanical Engineering

JSS Academy of Technical Education, Bangalore-560060
 TEXT BOOKS

• Mechatronics Electronic control system in Mechanical and Electrical Engineering, W Bolton,

Pearson Education, 1st Ed., 2005.
• Mechatronics-Principles, Concepts and Applications, Nitaigour Premchand Mahalik, Tata
McGraw Hill, 1st Edition, 2003

REFERENCE BOOKS:

• Mechatronics by HMT Ltd. - Tata McGrawHill, 1st Edition, 2000

Further Reference:
National Programme on Technology Enhanced Learning (NPTEL)
https://nptel.ac.in/courses/112103174/1 by Dr. S. N. Joshi (IITG)
 Learning Objectives

• Understand the evolution and development of Mechatronics as a discipline.

• Substantiate the need for interdisciplinary study in technology education.

• Understand the applications of microprocessors in various systems and to know the

functions of each element

• Demonstrate the integration philosophy in view of Mechatronics technology.

 Outcomes

• Illustrate various components of Mechatronics systems.

• Assess various control systems used in automation.

• Develop mechanical, hydraulic, pneumatic and electrical control systems.

MECHATRONICS

CHAPTER 1: Introduction to Mechatronics

 Module 1

Introduction: Definition, Multidisciplinary Scenario, Evolution of Mechatronics,

Design of Mechatronics system, Objectives, advantages and disadvantages of
Mechatronics

Transducers and sensors: Definition and classification of transducers, Difference

between transducer and sensor, Definition and classification of sensors, Principle of
working and applications of light sensors, proximity switches and Hall Effect
sensors.
 INTRODUCTION

• Mechatronics is a concept of Japanese origin (1970’s).

• The term Mechatronics coined by “Tetsuro Mori”.

• Defined as the application of electronics and computer technology to control the

motions of mechanical systems.

 INTRODUCTION

• 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.

 INTRODUCTION

• It concurrently includes all these disciplines.

 INTRODUCTION

Examples of Predominately Mechanical devices

Bimetallic strip
Ball valve
 INTRODUCTION
Examples of Mechatronics system

• Domestic washing machines

Passenger cars automobiles are equipped with safety

• Installations such as air-bags

• Parking (proximity) sensors

• Antitheft electronic keys

• Autofocus, auto-exposure camera etc.

 INTRODUCTION
Examples of Mechatronics system
 INTRODUCTION
Examples of Mechatronics system
 INTRODUCTION
Examples of Mechatronics system
 INTRODUCTION
Examples of Mechatronics system
 INTRODUCTION

Importance of Mechatronics in automation

• Today’s customers are demanding more variety and higher levels of flexibility
in the products
• Demands and competition in the market
• Essential to automate the manufacturing and assembly operations of a
product.
 INTRODUCTION
Evolution

Incorporates l/O devices like sensors and actuators, integrates electrical

First Level signals with mechanical action. E.g. Fluid valves and relays

Second Integrates microelectronics into electrically controlled devices.

Level E.g.: Cassette player

Incorporates advanced feed back functions. “Smart Systems”

Third Level E.g. Hard disk, CD drives, automatic washing machines

Intelligent control in mechatronic system

Fourth Level E.g. Fault Detection and Isolation (FDI) capability systems.
 INTRODUCTION
Basic Elements in Mechatronics system
 INTRODUCTION
Basic Elements in Mechatronics system
 INTRODUCTION
Basic Elements in Mechatronics system

• The actuators produce motion.

• The sensors detects the state of the system parameters, inputs and outputs.

• Digital devices control the system.

• Conditioning and interfacing circuits provide connection between the control

circuits and the input/output devices.

• Graphical displays provide visual feedback to users.

 INTRODUCTION

Basic Elements in Mechatronics system

• Actuators: D.C. motors; Stepper motors; Servomotor; hydraulics; pneumatics.

• Sensors: Switches; Potentiometer, Strain guage, Thermocouple; accelerometer etc.

• lnput signal conditioning and interfacing: Discrete circuits; Amplifiers, Filters; A/D, D/D.

• Digital control architectures: Logic circuits; Microcontroller, PLC, Sequencing and timing,

• Output signal conditioning and interfacing: D/D, A/D; Amplifiers, Power transistors ;

Power Opamps.
 INTRODUCTION
Embedded systems

• The term embedded system refers to where microprocessors

are embedded into systems.

• A microprocessor is a collection of logic gates and

memory elements that are not wired up as individual
components, but logical functions are implemented by means
of software.

• An embedded system is a microprocessor-based system that

is designed to control a range of functions.
• Not designed to be programmed by the end user
• E.g.: Washing Machine, Engine Management, ABS, FIP, Cell
phone
 Design Process

Design process for any system involves a number of stages.

1. The need

2. Analysis of the problem

3. Preparation of a specification

4. Generation of possible solutions

5. Selections of a suitable solution

6. Production of a detailed design

7. Production of working drawings

 Design Process

In designing mechatronic systems; one of the steps is the creation of a model of

the system, that predictions can be made regarding its behaviour with reference
to the inputs.

System: A box or block diagram which has an input and an output.

• Only concerned with the relationship between the output and the input.

E.g. of systems
 Mechatronic Design Process

The mechatronic design process consists of three phases:

• Modeling and simulation

• Prototyping

• Deployment / Life cycle

Mechatronic Design Process
 Advantages and Disadvantages of Mechatronics

Advantages Disadvantages

Cost effective and reliable product High initial cost of the system.

Imperative to have knowledge of

High degree of flexibility and productivity different engineering fields for design
and implementation.

Specific problems for various systems

Greater extent of machine utilisation. will have to be addressed separately
and properly.
Reduction in the capital expense due to Expensive to incorporate mechatronics
integration of complex systems. approach to an existing/old system
MECHATRONICS

CHAPTER 1: Transducers and Sensors

 Transducers and Sensors

• Definition and classification of transducers.

• Difference between transducer and sensor.

• Definition and classification of sensors.

• Principle of working and applications of light sensors.

• Proximity switches and Hall Effect sensors.

Sensors

Automotive Sensors
Sensors

• Sensor is an element which produces a signal relating to the quantity being

measured.
• An input device which provides an output (signal) with respect to a specific
physical quantity.

• A device that converts signals from one energy domain to electrical domain.
Sensors
Sensors Examples

• Dial indicator: the indicating spindle acts as a sensor/detector for displacement.

• Bourdon tube of a pressure gauge is twofold:

• Firstly to sense the pressure & secondly to give the output in the form of
displacement. Here the tube acts a sensor/detector transducer.

• Compressive load cell: the platform detects the force and gives an output in the
form of deflection.

This deflection may be further converted into an electrical output by strain gauges
(called secondary transducer).
Sensors
Smart Sensor

• Sensors that combined with signal conditioning and microprocessors are

referred as smart sensors.

Smart sensors Applications

• Communications
• Computations
• Multi sensing
• Self calibration
Sensors

The normal sensors have three crucial parts which are

• Sensing element (Transistor, Capacitors, Photo Diode etc).

• Conduction of signals and processing.

• Sensor Interface.
 Classification of Sensors

The sensors are classified into the following criteria:

1. Primary Input quantity (Measurand)

2. Transduction principles (Using physical and chemical effects)

3. Material and Technology

4. Property

5. Application
 Classification of Sensors

• Active Sensor: Active Sensors are those which require an external excitation

signal or a power signal. E.g.: LiDAR (Light detection and ranging), photoconductive cell.

• Passive Sensor: Do not require any external power signal and directly

generates output response. E.g.: Radiometers, film photography

Based on the means of detection

• Some of the means of detection are Electric, Biological, Chemical, Radioactive
etc.
 Classification of Sensors
• Sensors that are commonly used in various applications.

All these sensors are used for measuring one of the physical properties like
Temperature, Resistance, Capacitance, Conduction, Heat Transfer etc.

•Temperature Sensor •Smoke, Gas and Alcohol Sensor

•Proximity Sensor •Touch Sensor
•Accelerometer •Color Sensor
•IR Sensor •Humidity Sensor
•Pressure Sensor •Tilt Sensor
•Light Sensor •Flow and Level Sensor
•Ultrasonic Sensor
 Classification of Sensors

Based on the conversion phenomenon i.e. the input and the output.

• Some of the conversion phenomena are Photoelectric, Thermoelectric,

Electrochemical, Electromagnetic, Thermo-optic, etc.

• Analogue sensors: Produce an analog output.

• Digital Sensors: Work with discrete or digital data.
 Principle of working of Light sensors (Passive)

Light Sensors are photoelectric devices / Photo sensors that convert light energy (photons)
whether visible or infra-red light into an electrical signal.

Photodiodes

Applications
Smoke detectors, compact disc players, and televisions,
remote controls in VCRs, clock radios, street light
 Principle of working of Light sensors (Passive)
Photodiodes
• Are semiconductor junction, connected into a circuit in reverse

bias giving a very high resistance.

• With no incident light, the reverse current is almost negligible

and is termed the dark current.

• When light falls on the junction, extra hole–electron pairs are

produced and there is an increase in the reverse current and

the diode resistance drops.

• The reverse current is very nearly proportional to the intensity of

the light.
 Principle of working of Light sensors (Passive)
Phototransistors

• The phototransistors have a light-sensitive collector–base p–n junction.

• When there is no incident light there is a very small collector-to-emitter current.
• When light is incident, a base current is produced that is directly proportional to the light intensity.
This leads to the production of a collector current which is a measure of the light intensity.
• Phototransistor are connected in a Darlington arrangement with a conventional transistor, for
higher current gain.

In electronics, a multi-transistor
configuration called Darlington pair
 Principle of working of Light sensors (Passive)
Photoresistor:
A photoresistor (or light-dependent resistor, LDR, or photo-conductive cell) is
a light-controlled variable resistor. The resistance of a photoresistor decreases with
increasing incident light intensity (photoconductivity).
 Principle of working of Light sensors (Passive)
Photoresistor:
• As the light energy falling on the photoconductive
material increases, number of valence electrons
that gain energy and leave the bonding with the
nucleus increases.

• This leads to a large number of valence electrons

jump to the conduction band, ready to move with
an application of any external force like an
electric field.
 Principle of working of Light sensors (Passive)
Applications of Photoresistor:

• Automatic Street Lights

• Light meters in camera
• Light sensors
• Clock radios
 Principle of working of Proximity switches

A proximity sensor is a sensor able to detect the presence of nearby objects

without any physical contact.

The microswitch is a small electrical switch which requires physical contact and
a small operating force to close the contacts.

For example: A conveyor belt.

 Principle of working of Proximity switches

(a) Lever-operated (b) roller-operated (c) cam-operated switches.

 Principle of working of Proximity switches

• It consists of two magnetic switch contacts sealed in a glass tube.

• When a magnet is brought close to the switch, the magnetic reeds
are attracted to each other and close the switch contacts.

• It is a non-contact proximity switch.

Reed switch Applications: Checking the closure of doors, used with tachometers etc.
 Hall effect sensors

A Hall effect sensor is a device that is used to measure the magnitude of a

magnetic field.
• Its output voltage is directly proportional to the magnetic field strength through it.
• Hall effect sensors are used for proximity sensing, positioning, speed detection,
and current sensing applications

Principle
• When a beam of charged particles passes through a magnetic field, forces act on
the particles and the beam is deflected from its straight line path.

• This effect was discovered by E.R. Hall in 1879 and is called the Hall effect.
 Hall effect sensors
Working
• Consider electrons moving in a conductive plate with a magnetic field
applied at right angles to the plane of the plate.

• As a result of the magnetic field, the moving electrons are deflected to one
side of the plate, and that side becomes negatively charged, while the
opposite side becomes positively charged since the electrons are directed
away from it.

• This charge separation produces an electric field in the material.

• The charge separation continues until the forces on the charged particles
from the electric field just balance the forces produced by the magnetic
field.
 Hall effect sensors

• The result is a transverse potential difference V given by

B= magnetic flux density

I = current
KH = constant, Hall coefficient
t= plate thickness
 Hall effect sensors
• Applications
• Position sensing
• Automotive fuel level indicator
• Keyboard switch

A wheel containing two magnets passing by

a Hall effect sensor

Fluid-level Detector
Transducer / Gauges / Signal Generators / Pickups
Transducer / Gauges / Signal Generators / Pickups
• A device that converts variations in a physical quantity, such as pressure or
brightness, into an electrical signal, or vice versa.

• A transducer is an electronic device that converts energy from one form to

another.

• E.g. microphones, loudspeakers, thermometers, position and pressure sensors,

and antenna Excitation

Physical Qty. Transducer Electrical Output

Transducer
MECHANICAL DETECTOR -TRANSDUCER ELEMENTS

Mechanical detector-transducer elements are;

1. Elastic members/elements

2. "Mass" sensing elements

3. Thermal detectors

4. Hydro-pneumatic elements
Transducer
MECHANICAL DETECTOR -TRANSDUCER ELEMENTS

Elastic members / elements:

Works on the principle of direct tension or compression, bending and torsion.

The common elastic members/elements are

• Proving ring (stress ring).

• Elastic torsion member
• Springs
• Bourdon tube, Bellows, diaphragms
Transducer
MECHANICAL DETECTOR -TRANSDUCER ELEMENTS

Mass Sensing elements:

Works on the principle of inertia of a concentrated mass

The common Mass sensing members/elements are

• Accelerometers.
• Vibration pickups
• Manometers
Transducer
MECHANICAL DETECTOR -TRANSDUCER ELEMENTS

Thermal detectors: Temperature measuring devices

The common thermal detectors are;

• Glass thermometers.
• Pressure gauge thermometers
• Bimetallic thermometers
• Resistance thermometers
• Thermistors
• Pyrometers
• Thermocouples.
Transducer
MECHANICAL DETECTOR -TRANSDUCER ELEMENTS

Hydro-Pneumatic Sensors: Temperature measuring devices

The common Hydro-Pneumatic sensors are;

• Simple Float
Static conditions
• Hydrometer

• Orifices and Venturies

Dynamic conditions • Pitot tube
• Vanes
Transducer
Classification of Transducers

• Mechanical Transducers: Convert physical quantities into mechanical ones.

• Electrical Transducers: Transducers that convert physical quantities into

electrical.

• E.g. A thermocouple that changes temperature differences into a small voltage.

Linear variable differential transformer (LVDT) used to measure displacement

 Classification of Transducers

Transducer

Active Transducer Analogue

Based on the type of output
Digital
Passive Transducer
 Classification of Transducers

Based on electrical Principle

Variable-resistance type Variable-capacitance type Voltage-Divider type

• Strain • Capacitor microphone • Pressure-actuated voltage divider.

• Pressure gauges • Pressure gauge • Potentiometer position sensor.

• Thermistors • Dielectric gauge.

• RTD
Voltage-generating type Variable-inductance type
• Photoconductive cell

• Thermocouple • LVDT
• Piezoelectric pick-up • Reluctance pick-up
• Photovoltaic cell • Eddy current gauge
• Rotational motion tachometer
 Classification of Transducers

Active Self-generating type transducers. • Thermocouple, Piezoelectric

Transducer They develop their own voltage or current. pick-up, Photovoltaic cell

Passive Externally-powered transducer. • RTD, Thermistor, DT,

Transducer May absorb some energy. Photoemission cell

Convert input into analogue. • Thermocouple, Strain gauge,

Analogue O/p is continuous function of time. LVDT

Convert input into electrical output In form

Digital of pulse
 Terms associated with Transducers

Transducer Sensitivity: The relation between the measurand and the transducer
output signal.

• Sensitivity of a transducer should be usually as high as possible, for easier

measurements.
 Terms associated with Transducers

Specifications for Transducers

• Ranges available. • Mounting details

• Sensitivity. • Maximum depth.
• Squaring system. • Output for zero input.
• Maximum working temperature • Natural frequency.
• Linearity and hysteresis
• Temperature coefficient of zero drift
• Method of cooling employed
Difference between Sensor and Transducers

Sensors – the term sensor is used for

an element which generates a signal
which is proportional to the quantity
being measured.

Transducer – these are elements

when subjected to physical
change experience a related
change.
Difference between Sensor and Transducers
 Difference between Sensor and Transducers

Basis For
Sensor Transducer
Comparison

Senses the physical changes occurs in The transducer is a device which,

Definition the surrounding and converting it into a when actuates transforms the
readable quantity. energy from one form to another.

Components Sensor itself Sensor and signal conditioning

Detects the changes and induces the Conversion of one form of energy
Function corresponding electrical signals. into another.

Proximity sensor, Magnetic sensor,

Thermistor, Potentiometer,
Examples Accelerometer sensor, Light sensor,
Thermocouple, etc.
Barometer, Gyroscope etc.
End of Module